Nk - Guidance for the Approval and Type Approval of Materials and Equipment for Marine Use

Part I Chapter 1

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GUIDANCE FOR THE APPROVAL AND TYPE APPROVAL OF MATERIALS AND EQUIPMENT FOR MARINE USE

Part I GENERAL

Chapter 1 GENERAL

1.1 Application

1 This guidance applies to tests and inspection of materials and equipment for marine use for which advance approval or type approval by the NIPPON KAIJI KYOKAI (hereinafter referred to as “the Society”) are required by the relevant requirements in Rules for the Survey and Construction of Steel Ships, Rules for the Survey and Construction of Ships of Fibreglass Reinforced Plastics and Rules for Floating Docks, and their Guidances (hereinafter referred to as “Rules etc.”) 2 This guidance is, in principle, to apply to each manufacturing plant. 3 The confirmation survey of manufacturing and quality control procedure required in the guidance may be dispensed with partly or totally subject to the approval in accordance with “Rules for Approval of Manufacturers”.

1.2 Purpose

The purpose of this guidance is to specify the procedures for approval and type approval by the Society of the materials and equipment for marine use delivered from manufacturing plants as finished products in the course of examinations for the construction, materials, scantlings and workmanship of the hull, equipment and machinery required by 2.1.1, Part B of Rules for the Survey and Construction of Steel Ships excluding the examinations for hull outfitting work and machinery assembly and installation work carried out at shipyards or manufacturer’s shops.

1.3 General

In principle, new installation of materials which contain asbestos is to be prohibited. Where deemed as necessary by the Society, the installation may be allowed in such positions as shown below; (1) vanes used in rotary vane compressors and rotary vane vacuum pumps; (2) watertight joints and linings used for the circulation of fluid when, at high temperature in exceed of 350 or

pressure in excess of 7 MPa, there is a risk of fire, corrosion or toxicity; and (3) supple and flexible thermal insulation assemblies used for temperatures above 1,000. (4) where materials which contain asbestos are used, documents including the location and other detailed in

formation are to be submitted to the society.

Guidance for the Approval and Type Approval of Materials and Equipment for Marine use

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Chapter 2 DEFINITIONS

2.1 Approval

Approval means to certify for the manufacturers of the materials and equipment for marine use that the materials and equipment comply with this guidance by carrying out the examination, tests and inspection specified in this guidance for the materials and equipment.

2.2 Type Approval

Type Approval means to certify for the manufacturers of the materials and equipment for marine use that the materials and equipment comply with the provisions for the type approved products in this guidance by carrying out the examination, tests and inspection specified in this guidance for the materials and equipment. For type approved products, tests and inspection are not required to individual products.

2.3 Approval of Mass Produced Machinery and Equipment

Approval of Mass Produced Machinery and Equipment means of certify for the manufacturers that the machinery and equipment manufactured by mass production system comply with the provisions in this guidance by carrying out the examination, tests and inspection specified in this guidance, based on the requirements in 1.4.2, Part D and 1.2.1-3, Part H of Rules for the Survey and Construction of Steel Ships.

2.4 Approval of Manufacturing Process

Approval of Manufacturing Process means, on condition that the uniform quality of the products can be ensured, to certify for the manufacturers that the manufacturing process complies with the provisions in this guidance by carrying out the examination, tests and inspection specified in this guidance in advance for their typical sample.

2.5 Approval of Use

Approval of Use means, for the equipment for marine use to which the advance approval by the Society for their use is required by the Rules etc. before installed on board, to certify for the manufacturers that the equipment complies with the provisions in this guidance by carrying out the examination, tests and inspection for their typical sample.

2.6 Approval of Standardized Design

Approval of Standardized Design means a method for applying the requirement in 2.1.2-6, Part B of Rules for the Survey and Construction of Steel Ships and to certify for the manufacturers that the drawings and documents specifying the particulars, construction, dimensions and materials of equipment for marine use may be dealt with as the standard design, by conducting the approval for these drawings in advance.

2.7 Approval of Prototype

Approval of prototype means to certify for the manufacturers that machinery and equipment for marine use comply with the provisions in this Guidance by carrying out the examinations, tests and inspection against the prototype of these products which are required by the Rules or Guidance that prototype of products is to be approved by the Society in advance before products are sent to markets.

Part 1 Chapter 1

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Part 1 METALLIC MATERIALS

Chapter 1 APPROVAL OF MANUFACTURING PROCESS OF ROLLED STEELS

1.1 General

1.1.1 Scope 1 In accordance with the requirements in 1.2, Part K of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”), the requirements in this chapter apply to tests and inspection for the approval of manufacturing process of rolled steels as specified in Chapter 3, Part K of the Rules. 2 For those materials required to be approved by the Society under the requirements in 1.1.1-2, Part K of the Rules, the requirements of this chapter correspondingly apply to the tests and inspection for the approval of the manufacturing process of rolled steels. 3 The requirements of this chapter correspondingly apply to tests and inspection for the approval of semi-finished products such as slabs, blooms and billets for the rolled steels specified in preceding -1 and -2. 4 For the approval of manufacturing process of rolled steels for hull specified in 3.1, Part K of the Rules, when a confirmation of the weldability of a steel for which special consideration is given in a range of welding heat input, is made as a request by manufacturer’s option, the requirements in Chapter 1A apply to such confirmation.

1.2 Approval Application

1.2.1 Approval Application Form Manufacturer who applies for the approval of the manufacturing process of rolled steels and semi-finished products is to submit a copy of the approval application form (see Form 1-1) filled in with required data and information to the Society (branch office concerned).

1.2.2 Documents to be Submitted 1 Three copies each of the documents given in (1) and (2) are to be submitted together with the approval application form specified in 1.2.1. (1) Approval test plan (2) Technical data given in the following (a) through (k) ((a) through (f) and (k), in the case of the approval of

semi-finished products) (a) Data on works

i) Name and location of the works ii) General indications relevant to the background iii) Dimension and size of the works iv) Organizational chart and number of staff employed v) Estimated total annual production of finished and semi-finished products (for shipbuilding and for

other applications) (b) Data on quality control system

i) Organization and number of staff employed of the quality control department ii) Qualification of the personnel involved in activities related to the quality of the products iii) Items and methods for quality control system iv) Outline of system used for identification of materials v) Outline of equipment for mechanical tests, chemical analyses and metallography and relevant

calibration procedures vi) Outline of equipment for non-destructive tests and relevant calibration procedures


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vii) Certification of compliance of the quality system with ISO 9001 and 9002, if any (c) Data on steel products

i) Type of products and grades of steel ii) Maximum manufacturing thickness or dimensions iii) Deoxidation practice and system of constituent iv) Manufacturing standard for each chemical composition (if the system of constituent depends on grade,

thickness, heat treatment etc., the different ranges are to be specified, as appropriate.) v) Maximum carbon equivalent (Ceq) (this value is to be calculated by the formula specified in 1.5.2-2(6),

Part K of the Rules) vi) Maximum cold cracking susceptibility (Pcm) for higher strength grades with low carbon content C ≤

0.13% (this value is to be calculated by the formula specified in 1.5.2-2(6), Part K of the Rules) vii) Actual manufacturing records within the specific period (chemical composition, mechanical properties

and thickness or dimension are expressed in the form of histogram or statistics for each heat treatment) (d) Data on manufacturing process

i) Origin and storage of raw materials ii) Flow chart of the manufacturing process iii) Outline of major manufacturing facilities (including control methods) iv) Storage of finished and semi-finished products

(e) Data on steel making process i) Outline of steel making process ii) Type and capacity of steel making furnace and the number of daily charge iii) Raw materials and sub materials iv) Deoxidation and refining practice v) Secondary refining practice vi) Casting methods (ingot casting or continuous casting) vii) Scarfing and discarding procedures of ingot or semi-finished products viii) Size and weight of ingot or semi-finished products

(f) Additional data in the case of applying continuous casting i) Outline of continuous casting machine (including type of casting machine, number of strand, casting

practice, casting temperature, casting speed etc.) ii) Preventive methods for re-oxidation of charge iii) Reduction methods for non-metallic inclusions iv) Preventive methods for segregation v) Presence of electromagnetic stirring vi) Presence of soft reduction system

(g) Data on reheating process i) Outline of heating furnace (including type and capacity) ii) Heating temperature and holding time

(h) Data on rolling process i) Outline of rolling machine (including type and capacity of rolling machine and control methods of

thickness and temperature) ii) Starting and finishing temperature of rolling iii) Reduction ratio iv) Outline of descaling device

(i) Additional data in case of applying CR or TMCP. i) Outline of CR or TMCP process (including control method of thickness and temperature and

calibration method of the control equipment) ii) Re-crystallization temperature, Ar3 temperature and its determination methods iii) Rolling pass schedule (including thickness and temperature at the beginning and the end of the passes

besides at each pass) iv) Outline of Accelerated Cooling (AcC) (including outline of cooling system, cooling method,

temperature range, cooling speed and a cooling measure in a uniform way)

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v) Actual manufacturing records within the specific period (in addition to (c)vii) above, description of relation between tensile strength and carbon equivalent, and variation of mechanical properties in direction of rolling, direction of the steel width and direction of thickness)

vi) Recommendation relevant to cold and hot working after shipment (where only the case of the special attention is needed)

vii) Range of available welding heat input (where the upper limit of welding heat input exceeds 50 kJ/cm) (j) Data on heat treatment process

i) Outline of heat treatment furnace (including type and capacity) ii) Heating temperature and holding time iii) Accuracy and calibration of temperature control device

(k) Other data deemed necessary by the Society 2 Where any part of manufacturing process is assigned to other works, additional information relevant to the name and address of the works in question together with the organization and method of inspection for the materials of which the manufacturing process is assigned are to be included. 3 Notwithstanding the requirements in preceding -1, where the documents are duplicated by the ones at the previous approval for the same type of products, grades, deoxidation practice, etc., part or all of the documents may be omitted. However, approval test specified in 1.4 is required, approval test plan specified in -1(1) is not be exempted from submission.

1.3 Preliminary Examination

1.3.1 Approval of Test Plan The Society examines the approval test plan submitted in accordance with the requirements in 1.2.2-1, and where deemed appropriate, the plan is approved and returned to the manufacturer.

1.3.2 Confirmation of Manufacturing and Quality Control Procedure 1 The Society may carry out surveys of the actual situation of the manufacturing plant on the basis of the data submitted according to the requirement of 1.2.2 as deemed necessary. In this case, the manufacturer is to provide the necessary information related to this survey. 2 The time of the survey, in accordance with the preceding -1, is to correspond, as a rule, to either the time of rolling of the steels or the time when the approval test is carried out.

1.4 Approval Test

1.4.1 Extent of the Approval Tests 1 Approval for the manufacturing process of rolled steels or semi-finished products is to be the following (1) and (2) if deemed appropriate by the Society. (1) Rolled steels for hull, rolled steels for low temperature service and high strength quenched and tempered rolled

steels for structure (including their semi-finished products) Approval for any grade of steels may also covers approval for any lower grade of steels (of which specific temperature of impact test is higher than that of test sample) in the same strength level provided that kind, deoxidation practice, system of constituent, heat treatment, steel making process, steel casting process and maximum manufacturing thickness or dimensions (except kind and heat treatment, in the case of semi-finished products) are same. For higher tensile steels for hull, in addition to above, approval of one strength level may also covers the approval of the same grade and below in the strength level immediately below.

(2) Rolled steels other than those of preceding (1) (including their semi-finished products) Approval for any strength level of steels may also covers approval for any lower strength of steels (of which specific yield strength level is lower than that of test sample) provided that kind, deoxidation practice, heat treatment, steel making process, steel casting process and maximum manufacturing thickness or dimensions (except kind and heat treatment, in the case of semi-finished products) are same and range of chemical composition is similar.

2 Approval for manufacturing process of rolled steels covers approval for semi-finished products with the same


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grade, deoxidation practice, system of constituent, steel making process and steel casting process.

1.4.2 Selection of Test Samples 1 Test samples used for approval test of rolled steels or semi-finished products are to be selected according to the following (1) and (2) : (1) Test samples are generally to be selected for each grade and kind by each charge of rolled steels of which

deoxidation practice, system of constituent, heat treatment, steel making process and steel casting process are same. In case of semi-finished products, test samples are generally to be selected for each grade by each charge of semi-finished products of which deoxidation practice, system of constituent, steel making process and steel casting process are same.

(2) In case of ingot casting, test samples are to be selected from the steels which are directly rolled from top of a ingot, and in case of continuous casting, test samples are to be selected from the steels which are directly rolled from one of any semi-finished products, except where specially approved by the Society. Test samples of semi-finished products are also to be selected corresponding to each casting process.

2 The plate thicknesses or dimensions of test samples are to be the maximum manufacturing thicknesses or dimensions. Moreover, in case of the steel plates are manufactured from the continuous casting slabs, the maximum manufactured thickness is to be determined, with the reduction ratio is 6 as standard. However, upon consideration of the manufacturing process, the reduction ratio may be reduced to 4 (in case of steel plate of over 50mm thickness may be reduced to 3). 3 Where the maximum manufacturing thickness of rolled steels for hull, rolled steels for low temperature service and quenched and tempered high tensile rolled steels, is 50mm, 40mm and 70mm, and over respectively, and in case of first approval of at least one item of deoxidation practice, system of constituent, heat treatment, steel making process and steel casting process, Society may request an additional test samples of which thickness is indicated with a mark in Table 1.1-1 or other proper thickness, in addition to the test samples in accordance with -2.

Fig. 1.1-1 Selection of Test Samples (an example)

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Table 1.1-1 Standard Thickness and Dimensions of Test Samples

Note :

(1) The shaded portion and cross shaded portion show the range or thickness for which normalizing of quenching and tempering treatment have been specified for steel plates respectively, while the unshaded portion shows the as-rolled condition. However, quenching and tempering is included for KE40, KF32, KF36 and KF40, and normalizing and tempering is included for KL2N30, KL3N32 and KL5N43, and KL9N53 is to be double normalized and tempered.

(2) See 1.4.2-3.

1.4.3 Details of Test 1 Approval tests for each of rolled steels are to be performed for each test item indicated with a mark in Table 1.1-2 and the test procedure and judgement standard are to be accordance with Table 1.1-3. However, when deemed necessary by the Society, Society may request the increase of test piece, addition of test item (except the test item indicated in Table 1.1-2 which is included the test related to hot workability, fatigue test, weld cracking test etc.) and submission of proper technical information. 2 In case of the test is not able to carry out at the works, the test is to carry out at proper test organization after


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obtaining the approval of the Society. 3 In case of following (1) or (2), Society considers these content and may omit the part or all of the approval tests. (1) Changes in the approval contents specified in 1.5.4. (2) The manufacturing process and the test result have been approved by the other society and the manufacturer has

a data showing actual manufacturing records within the specific period. (chemical composition, mechanical properties and thickness or dimension expressed in the form of histogram or statistics)

Table 1.1-2 Approval Test Items for Rolled Steels

Rolled steels Kind of test (See Note(1))

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v) (w) (x)Rolled steels KA

for hull KB

KD

KE

KA32, KA36, KA40

KD32, KD36, KD40

KE32, KE36, KE40

KF32, KF36, KF40

Rolled steels for boilers

KP42 ~ KPA56

Rolled steels for pressure

vessels

KPV24~KPV50

Rolled steels for low

temperature service

KL24A~KL9N60

Rolled stainless steels

KSUS304~KSUS347

Round bars KSBC31~KSBC70

for chains KSBCR3, KSBCR3S, KSBCR4

Rolled steel bars for boiler

KPS42B~KPS46B

Rolled carbon steel bars

KSFR41~KSFR78

Rolled low alloy steel

bars

KSFAR60~KSFAR110

Quenched and tempered HT

steels

KA43~KF70N

Stainless clad Base metal KA~KF40 steels Cladding

metal KSUS304~ KSUS347

Note : (1) Kind of Test

Base metal test (a) Chemical analysis (b) Sulphur print (c) Macro-structure (d) Micro-structure (e) Austenite grain size (f) Ferrite grain size (g) Hardness test (h) Tensile test (i) Bend test

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(j) Shearing strength test (k) Charpy impact test (l) Strain aging Charpy impact test (m) Hydrogen embrittlement test Brittle fracture test (n) CTOD test (Crack Tip Opening Displacement test) (o) Large scale brittle fracture test (p) NRL drop weight test Weldability test (q) Butt welding tensile test (r) Butt welding impact test (s) Welding hardness test High temperature characteristics test (t) High temperature tensile test (u) Creep test Corrosion resistance test (v) Corrosion test Non-destructive test (w) Ultrasonic test Dimensional measurement (x) Dimensional measurement

(2) Approval test items for semi-finished products are to be chemical analysis, sulphur print and macro-structure. (3) For the rolled steel which is applied TMCP heat treatment may be requested SR tensile test in addition to those tests

given in the table. (4) For steel materials with through thickness properties as specified in 3.11, Part K of the Rules, the thickness

directional tensile test, microscope examination for non-metallic inclusions, ultrasonic test are required in addition to those tests given in the table.

(5) For steel materials with brittle crack arrest properties as specified in 3.12, Part K of the Rules, temperature gradient ESSO tests or double tension tests are required.

(6) For kind of product other than steel plates, the strain aging Charpy impact test, NRL drop weight test, CTOD test and large scale brittle fracture test are not required, unless otherwise specified. However, where cast piece from the continuous casting method is used, each test item of the macro-structure of the cast piece and its sulpher print may need to be added.

(7) The CTOD test, the strain aging Charpy impact test are required by the Table for round of offshore chains, these tests may be omitted in case appropriate records prepared by the manufacture are available. In this case, such records and documents on heat treatment sensitivity, resistant to strain aging, temper embrittlement are to be submitted to the Society.

(8) The CTOD test, large scale brittle fracture test (double tension test, ESSO test, deep notch test etc.), high temperature tensile test and creep test as specified in the table are performed for the purpose of evaluating low temperature toughness and high temperature characteristics, and these tests may be omitted in case appropriate records prepared by the manufacturer are available or in case the Society deems the tests unnecessary.


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Table 1.1-3(a) Approval Testing Method and Acceptance Criteria

Approval test item

Selected location of test

samples (1) (2)

Length direction

of test specimen

(3)

Testing method Acceptance criteria

Base metal test Chemical analysis Top －

JIS G 0321 or equivalent method. Ladle analysis and product analysis (5) are to be performed for elements specified in Part K of the Rules, and other elements (4) as deemed necessary.

Chemical composition by ladle analysis is to comply with the requirements in Chapter 3, Part K of the Rules.(6)

Sulphur print Top Transverse

JIS G 0560 or equivalent method. Length is to be 600 mm or greater.

Bias etc. deemed to have negative effects are not to be present.

Microscopic examination for non- Top Transverse JIS G 0555 or equivalent method. To be as deemed

appropriate by the Society. metallic inclusions Bottom Transverse Macro-structure Top Transverse JIS G 0553 or equivalent method. Bottom(7) Transverse

Micro-structure Top － Microscopic photographs (approx. 100x) of base metal, Bottom － joining part and cladding metal are to be taken.

Austenite grain size Ferrite grain size Top －

JIS G 0551，JIS G 0552, ASTM E 112 or equivalent method.(8) Magnification of microscopic photographs are to be, as a rule, 100x (9). The grain size is required for each microscopic photographs.

Hardness test Top －

In accordance with the requirements in Part K of the Rules. Hardness distribution in the thickness direction is to be measured in the case of stainless clad steel.

For decisions other than those specified according to Chapter 3, Part K of the Rules, to be as appropriate by the Society.

Tensile test Top(10) Transverse

In accordance with the requirements in Part K of the Rules.(11) To meet the requirements in Chapter 3, Part K of the Rules.

Bend test Bottom Transverse

In accordance with the requirements in Part K of the Rules.(12) To meet the requirements in Chapter 3, Part K of the Rules.(12)

SR tensile test Top Parallel To be as deemed appropriate by the Society. However, the test

specimens which have been maintained for 2 minutes To be as deemed appropriate by the Society.

Bottom Parallel per 1 mm of thickness at 600 °C (minimum 60 minutes), as a rule, to be used

Thickness directional Top Thickness In accordance with the requirements in Part K of the Rules. To meet the requirements in Chapter 3, Part K

tensile test Bottom direction of the Rules. Shearing strength test Top

－ In accordance with the requirements in Part K of the Rules. To meet the requirements in

Chapter 3, Part K Bottom － of the Rules

V-notch Charpy impact test (13) Top(10) Parallel Using U4 test specimen(14), the transition temperature curve of

the absorbed energy and fracture surface ratio is to be deter For decisions other than those specified according

Transverse mined by testing three pieces at each temperature in addition to the lateral expansion of test specimen. Furthermore, the

to Chapter 3, Part K of the Rules to be as

Bottom Parallel test emperature is to include the temperature(15) as specified in Part K of the Rules, and its interval is to be 10 ~ 20.(7)

appropriate by the Society.

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Table 1.1-3(b) Approval Testing Method and Acceptance Criteria (continued)

Approval test item

Selected location of test

samples (1) (2)

Lengthdirection

of test specimen

(3)


Base metal test Strain aging charpy impact test(16) Top(10) Parallel

Using U4 test specimen(14), the transition temperature curve of the absorbed energy and fracture surface ratio is to be determined by testing three pieces at each temperature in addition to the lateral expansion of test specimen. Furthermore, the test temperature is to include the temperature(15) as specified in Part K of the Rules, and the test specimens which have been maintained for one hour at 250 after strain of 5% or 10% have been applied is, as a rule, to be used.

To be as deemed appropriate by the Society.

Hydrogen Top Parallel

In accordance with the requirements in Part K of the Rules. In accordance with the requirements in Part K of

embrittlement test Bottom Parallel the Rules

Brittle fracture test COD test Large scale brittle Fracture test

Top Parallel To be consulted with the Society the dimension of test specimen, test condition etc. When newly performing tests at the time of approval.


NRL drop weight test Top Parallel ASTM E 208 or equivalent method.(17)

Butt welding tensile test(16)(19) Top

Transverse

Tensile test is to be carried out for one test specimen of U2A or U2B In accordance with the requirements in Chapter 4, Part M of the Rules.

Weldability(18) Butt welding impact test(16)(19) Top

for weldingdirection

One set of three U4 test specimens is to be selected from at weld junction, 2 mm from weld junction, 5 mm from weld junction and 20 mm from weld junction of position of notch respectively, and tested at temperature in accordance with Part K of the Rules.


Welding hardness test Top －

Rolled steels for hullRolled steels for low temperature serviceHigh strength quenched and tempered rolled steel plates for structure(Each plate is including steel flats not less than 600 mm in width)

At section of butt welding joint, welding hardness test is measured 0.7 mm pitch by HV5 from weld junction to base metal along with the two parallel line which are 1 mm inside from the both surface of base metal.

In case of rolled steels for hull, the value of maximum hardness is not to be over 350. For other steel plates are to be as appropriate by the Society.

Rolled steels other than the mentioned above

JIS Z 3101or equivalent method.


High temperature characteristics test

High temperature tensile test Creep test

Top Parallel

To be consulted with the Society on the dimension of test specimen, test condition etc., when newly performing tests at the time of approval.


Corrosion resistance test

Corrosion test Top － JIS G 0575, G 0576 and G 0591 or equivalent method.

Stainless crad steels JIS G 0601 or equivalent method. To meet the requirements of

class F of JIS G 0601 Non-destructive test

Ultrasonic test or Eddy current test

All surface

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Steel with consideration for thickness directional characteristics

In accordance with the requirements in Chapter 3, Part K of the Rules.

In accordance with the requirements in Chapter 3, Part K of the Rules.

Round bars for chains JIS G 0801 and JIS G 0202 or equivalent method.

To be free from any defects deemed to have negative effect.

Note : (1) In case of ingot casting, “Top” means edge of top side of ingot for length direction specified in 1.4.2-1(2), “Bottom”

means edge of another side. In case of continuous casting, any edge is available of both edge for length direction specified in 1.4.2-1(2).

(2) Selected position at width direction or section for each kind is to meet the requirements in 3.1.6-4, Part K of the Rules.

(3) For steel products other than steel plate (i.e. steel sections, steel bars), when it is difficult to be taken test specimens with their longitudinal axis transverse to the rolling direction, test specimens may be taken parallel to the rolling direction subject to the approval with the Society.

(4) In case of rolled steels for hull, the analysis is to be carried out for As, Sn, B and Sb. (for B and Sb in case of steel making by electric furnace or open hearth furnace)

(5) The sample is to be selected from tensile test specimen. (6) Excess difference on the chemical compositions between ladle analysis and product analysis is not to be accepted.


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(7) For the continuous casting billet before rolling, macrostructure test may be omitted at the bottom portion. (8) In case of the steels over 40mm in thickness, the tests are to be carried out at the surface, the position of one forth in

thickness and the middle of thickness. (9) In case of the ferrite grain size number over 10, microscopic photographs (500x) is to be taken. (10) In case of hot coil, test sample is to be selected from middle of length direction specified in 1.4.2-1 in addition. (11) In case of tensile test specimens of bar taken from the steels over 40mm in thickness, test specimens are to be taken

from the middle of thickness in addition to the position in accordance with the requirements of Part K of the Rules. (12) Shapes and sizes of test specimen, testing method and judging criteria for the materials for which bend test is not

prescribed in the Part K of the Rules, are left to the discretion of the Society. (13) V-notch Charpy impact test specimens for stainless clad steels are to be taken from the base material. (14) In case of tensile test specimens over 40mm in thickness, test specimens are to be taken from the middle of thickness

in addition to the position in accordance with the requirements of Park K of the Rules. (15) In case of rolled steels for hull, at least test temperature is to be included the temperature of Table 1.1-4. (16) In case of other than steel plates (including steel flats not less than 600mm in width), the test may be omitted. (17) The photograph of test specimen after the test is to be taken. (18) In test records, the figure indicated the details of edge preparations, layer or pass sequence and measuring position of

hardness are to be included, in addition to macroscopic photograph of welded section, welding procedure, welding consumables (brand, mark, shielded gas, backing etc.), welding parameter (amperage, voltage, welding speed, heat input, current etc.), preheating temperature and interpass temperature. However, where only requested maximum hardness test, these requirement may not be applied.

(19) The test is generally to be carried out by each test specimen sampling from two butt weld test assemblies which are different of welding heat input (about 15 kJ/cm and 50 kJ/cm). Welding direction is to be transverse to the direction of rolling of test assemblies for rolled steels for hull and to be parallel to the direction of rolling of assemblies for rolled steels for low temperature service and high strength quenched and tempered rolled steel plates for structure.

Table 1.1-4 Impact Test Temperature for Rolled Steel for Hull

Grade Direction of the test specimens

Test temperature ()

KA, KB, Parallel +20 0 -20 KA32, KA36, KA40 Transverse +20 0 -20

Non stain KD, Parallel 0 -20 -40 aging KD32, KD36, KD40 Transverse 0 -20 -40

specimens KE, Parallel 0 -20 -40 -60 KE32, KE36, KE40 Transverse -20 -40 -60 KF32, KF36, KF40 Parallel -20 -40 -60 -80 Transverse -40 -60 -80 KA32, KA36, KA40 Parallel +20 0 -20

Strain aging

KD, KD32, KD36, KD40

Parallel 0 -20 -40

specimens

KE, KE32, KE36, KE40

Parallel -20 -40 -60

KF32, KF36, KF40 Parallel -40 -60 -80

1.4.4 Attendance of the Society’s Surveyor for Test The Society’s Surveyor is to be present, as a rule, when the test samples for the approval test are being identified and when the approval test is being carried out.

1.4.5 Test Reports 1 After completion of the approval test, the manufacturer is to produce a report of the approval test and is to submit three copies to the Society (branch office concerned) upon receiving confirmation by the Society’s Surveyor.

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2 The report of the approval test of the preceding -1 is to be appended with work records relating to steel making, ingot-making (casting), rolling and heat treatment of the test samples.

1.5 Approval

1.5.1 Notification and Announcement of Approval 1 The Society grants approval of the manufacturing process of rolled steels or semi-finished products which have been deemed appropriate on the basis of the reports of the Surveyor and documents submitted in accordance with requirements in 1.2 through 1.4. In this case, a “Certificate of Approval” is published including the name of works, kind of rolled steels, term of validity of approval etc. and the approved content etc. is described in “Particulars of Approval Conditions”. 2 Among those data submitted in accordance with the requirements in 1.2.2 and 1.4.5 which the Society deems necessary, a seal of approval is stamped and returned to the applicant. 3 Once a year, the Society announces rolled steels and semi-finished products which have been granted approval in the form of a table.

1.5.2 Validity of Approval Valid term of the “Certificate of Approval” specified in 1.5.1-1 will be 5 years from the date of approval. In case when the renewal of approval is carried out in accordance with the requirements in 1.5.3, valid term will be 5 years from the next day after the expiry date of the previous validity (hereinafter referred to as “date of renewal”).

1.5.3 Renewal of Approval 1 In case of application for renewal of approval, the applicant is to submit a “Certificate of Approval” (original) and three copies of the data showing actual manufacturing records (chemical composition, mechanical properties and thickness or dimension expressed in the form of histogram or statistics) of the rolled steels or semi-finished products within the specific period together with application form (Form 1-2). 2 The Society conducts the factory inspection. However, the Society may omit the factory inspection when actual manufacturing records are found to be satisfactory. 3 The factory inspection specified in -2 is to be completed within the valid term of “Certificate of Approval” in principle. However, for unavoidable circumstance, the factory inspection may be completed within a period of 3 months after the valid term upon the approval by the Society. 4 The Society is to examine the data showing actual manufacturing records specified in -1 and the result of factory inspection specified in -2, and if the Society considers them appropriate, is to approve the renewal of validity. 5 In case there is no data showing actual manufacturing records of rolled steels or semi-finished products from the previous date of renewal (In case of first renewal, the date of approval) or the Society deems necessary, the Society may renew the approval considering following (1) or (2) in addition to the result of factory inspection specified in -2. (1) Data of similar grade of products or semi-products (2) Result of approval test which newly carried out in accordance with the requirements in 1.2 through 1.4

1.5.4 Changes in the Approved Content 1 In case of changes in the approved content such as those given in the following (1) through (9) are occurred, in response to the content of changes, three copies of documents corresponding to the requirements in 1.2.2 are to be submitted to the Society, in addition to a copy of “Application for Changes in the Approved Content of Manufacturing Process of Rolled Steels” and a “Certificate of Approval” (original). (1) Addition to material grades (2) Changes in the steel making process (3) Changes in the casting making process (4) Changes in the rolling process (5) Changes in the limits of thickness (6) Changes in the heat treatment process (7) Changes in the chemical composition, added element etc. (8) In case of a part of manufacturing process (rolling, heat treatment etc.) is assigned to other works (9) Use of semi-finished products manufactured by other works


－14－

2 Upon studying the items of changes in approved content specified in -1, the Society requests the factory inspection and approval test in accordance with the requirements in 1.4 as necessary. 3 The Society is to examine the submitted data specified in -1 and reports of factory inspection and approval test specified in -2, and if the Society considers them appropriate, is to approve the changes in the approved content. In this case, as a rule, the validity of the “Certificate of Approval” specified in -1 is not changed.

1.5.5 Revocation of Approval In case any of the following (1) through (5) is relevant, the Society may revoke approval of the manufacturing process based on the requirements in this Chapter and give notice of the revocation to the manufacturer. The manufacturer which noticed the approval is withdrawn is to return “Certificate of Approval” and “Particulars of Approval Conditions” in question to the Society. (1) When the manufacturer does not pay the approval fees. (2) When the rolled steels and semi-finished products, whose manufacturing process has previously been granted

approval, no longer conform to the given requirements due to amendments or implementation of conventions, law, rule and regulations.

(3) In one case of following (a) through (e), when the manufacturer does not take a proper action in spite of the Society requests the investigation and improvement etc. (a) When the unstable quality is recognized at tests or inspections (b) When the harmful defects caused by the material in the process of being worked after shipment are

recognized (c) When the damages caused by the material at working condition are recognized (d) When the shortcomings are recognized on the quality system or manufacturing control system (e) When the approved content described on the “Particulars of Approval Conditions” specified in 1.5.1-1 were

changed without the permission of the Society (4) When manufacturers have not been carried out the renewal of approval according to the requirements in 1.5.3. (5) When a request for revocation is made by the manufacturer.

1.6 Dealing after Approval

1.6.1 General Rolled steels being conformed to meet the requirements of this chapter are to be dealt with as “an approved case” in the requirements in 2.2.1-1, Part K of the Rules, unless otherwise specified by the Society.

Part 1 Chapter 1

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Form 1-1


－16－

Form 1-2

Part 1 Chapter 1A

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Chapter 1A WELDABILITY CONFIRMATION OF ROLLED STEELS FOR HULL

1A.1 General

1A.1.1 Scope 1 In accordance with the provisions in 1.1.1-4, the requirements in this chapter apply to the weldability confirmation of rolled steels intended for welding with high heat input over 50 kJ/cm as a request by manufacturer’s option, for the approval of manufacturing process of rolled steels for hull specified in 3.1, Part K of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”). 2 For the weldability confirmation, the requirements in this chapter are applied provided that: (1) the Society confirms that the rolled steels have a prescribed weldability by tests under the manufacturer’s

specific welding conditions; and (2) conditions and applicable range for the approval of welding procedures and related specifications by the

provisions of Part M of the Rules are not restricted by “Weldability Confirmation Records” by the provisions in this chapter.

3 The time of the weldability confirmation may be different from that of approval of manufacturing process specified in Chapter 1 in this part. 4 The requirements provided in Chapter 1 in this part are applicable unless otherwise specified in this chapter.

1A.2 Application of the Weldability Confirmation

1A.2.1 Application Form Manufacturer who applies for the weldability confirmation of the rolled steels is to submit a copy of the application form (see Form 1-3) filled in with required data and information to the Society (branch office concerned).

1A.2.2 Documents to be Submitted 1 Three copies each of the documents given in (1) and (2) are to be submitted together with the application form specified in 1A.2.1. (1) Confirmation test plan (2) Technical data given in the following (a) through (d)

(a) Data on steel products i) Type of products and grades of steel ii) Range of manufacturing thickness or dimensions iii) Deoxidation practice and fine grain practice iv) Standard for chemical composition (if the system of constituent depends on grade, thickness, heat

treatment, etc., the different ranges are to be specified, as appropriate.) v) Maximum carbon equivalent ( eqC ) and maximum cold cracking susceptibility ( cmP ) (this value is to

be calculated by the formula specified in 1.5.2-2(6), Part K of the Rules) vi) Actual manufacturing records within the specific period (tensile and Charpy impact tests are expressed

in the form of histogram or statistics for each heat treatment) (b) Items for control system in accordance with manufacturing process to prevent deterioration of toughness of

heat affected zone (chemical composition, steel making process, steel casting process, steel rolled process, heat treatment, etc. are to be specified)

(c) Items for control system in accordance with welding procedure to improve strength and toughness of welded joints (where the case is needed)

(d) Other data deemed necessary by the Society 2 Notwithstanding the requirements in preceding -1, where the following documents are duplicated, part or all of the documents to be submitted may be omitted. However, confirmation test specified in 1A.4 is required,


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confirmation test plan specified in -1(1) is not to be exempted from submission. (1) Documents submitted for approval of manufacturing procedure of the rolled steels (2) Documents submitted of other steels, different from type of products, grades of steels, heat treatment, etc., that

are already confirmed with weldabilty by the Society

1A.3 Preliminary Examination

1A.3.1 Approval of Test Plan The Society examines the confirmation test plan submitted in accordance with the requirements in 1A.2.2-1(1), and where deemed appropriate, the plan is approved and returned to the manufacturer.

1A.4 Confirmation Test

1A.4.1 Extent of the Confirmation Tests Confirmation tests of rolled steels in the same manufacturing process may be the following (1) and (2) if deemed appropriate by the Society. (1) Results of confirmation tests carried out for two steels of different grade in the same strength level (two steels

different in the requirements of impact test temperature) can cover that for steels of intermediate grade in the same strength level.

(2) In addition to the provisions in preceding (1), for high tensile steels, such results can cover following steels: (a) steels of same grades in the strength level immediately below the level of the tested steels; and (b) steels of intermediate grade of the tested grades in the strength level immediately below the level of the

tested steels.

1A.4.2 Test Assemblies 1 Test assemblies of confirmation tests are generally to be two test assemblies of the different thickness. In this case, thinner thickness of test assemblies is not to be more than one-half of thicker plates. 2 Dimensions of test assemblies are to be sufficient to take required test specimens. 3 Welding direction is generally to be transverse to the plate rolling direction of test assemblies. 4 The welding of test assemblies should be as far as possible in accordance with the normal practices applied at shipyards.

1A.4.3 Details of Test 1 Test items, testing method and acceptance criteria for the confirmation test are to be accordance with Table 1.1A. However, when deemed necessary by the Society, the Society may request the increase of test piece, addition of test item (including CTOD test, deep notch test, cold cracking test, ESSO test, HAZ tensile test etc. other than those indicated in Table 1.1A) and submission of proper test organization after obtaining the approval of the Society. 2 In case of the test is not able to carry out at the works, the test is to carry out at proper test organization after obtaining the approval of the Society. 3 In case of following (1) or (2), the Society considers these contents and may omit part or all of the approval tests. (1) Changes in a part of manufacturing process or manufacturing condition of steels the weldability of which have

been already confirmed by the Society (2) The weldability confirmation and the test result have been approved by other society

1A.4.4 Attendance of the Society’s Surveyor for Test The Society’s Surveyor is to be present, as a rule, when the test assemblies for the confirmation test are being welded and when the confirmation test is being carried out.

1A.4.5 Test Reports 1 After completion of the confirmation test, the manufacturer is to produce a report of the confirmation test and is to submit three copies to the Society (branch office concerned) upon receiving confirmation by the Society’s Surveyor. 2 The report of the confirmation test of the preceding -1 is to be appended with work records relating to steel

Part 1 Chapter 1A

－19－

making, ingot-making (casting), rolling and heat treatment of the test assemblies. In addition, the report of the confirmation test is to be appended with the following records relating to welding of the test assemblies. (1) Welding method (2) Welding position (3) Welding consumables (manufacturer, brand, backing, grade, diameter of wire, shielded gas etc.) (4) Number of electrodes and arrangement, layer or pass sequence and welding parameter (current, amperage,

voltage, welding speed, heat input, etc.) (5) Types and dimensions of edge preparations (6) Preheating and interpass temperature

Table 1A.1 Confirmation Test Item, Testing Method and Acceptance Criteria

Confirmation test item

Length direction of test specimen(2)


Macroscopic test(1) Transverse JIS G 0553 or equivalent method. Absence of cracks, lack of penetration, lack of fusion and other injurious defects.

Microscopic test Transverse

Along mid-thickness line across transverse section of the weld, one micrograph with x100 magnification is to be taken at each position of the weld metal centreline, fusion line and at a distance 2, 5, 10 and 20 mm from the fusion line to base metal.


Hardness test(1) Transverse

Along two lines across transverse weld section 1 mm beneath plate surface on both face and root side of the weld, indentations by HV5 are to be made at weld metal centreline, fusion line and each 0.7 mm position from fusion line to unaffected base metal (minimum 6 to 7 measurements for each heat affected zone).

The maximum hardness value is not to be over 350.

Butt welding tensile test

TransverseTensile test is to be carried out for two test specimens of U2A and U2B.

In accordance with the requirements in Chapter 4, Part M of the Rules.

Butt welding bend test TransverseTwo transverse test specimens of UB-2 are to be bent through an angle of 120 degrees over a former having a radius of 2 times the thickness of test specimens.(3)


V-notch Charpy impact test

Transverse

Charpy impact specimens of U4 (three specimens for one set) are to be taken within 2 mm below plate surface on face side (in case of both sides are to be welded, final welded side) of the weld with the notch perpendicular to the plate surface. These specimens transverse to the weld is to be taken with the notch located at the weld junction and 2 mm, 5 mm and 20 mm from weld junction of position of notch respectively. These specimens are to be tested at temperature in accordance with Part K of the Rules. (4) (5) (6)


Visual inspection - Visual inspection of welded parts is to be carried out. Over all welded surfaces are to be uniform and free from injurious defects such as cracks, undercuts, overlaps etc.

Note : (1) The figures of macroscopic photograph and the position of hardness test are to be included in a report of the

confirmation test. (2) Length direction of test specimen is the direction against welding line.


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(3) For plate thickness up to 20 mm, two butt welding bend specimens may be replaced to one face bend and one root bend specimens of UB-1.

(4) When deemed necessary by the Society, the Society may request submission of transported temperature curve of energy and crystal defect par.

(5) For steel plate with thickness greater than 50 mm or one side welding for plate thickness greater than 20 mm, one additional set of the specimens is to be taken from the root side of the weld.

(6) Test temperature may be different degrees subject to the approval with the Society.

1A.5 Weldability Confirmation

1A.5.1 Publication of the Confirmation Records 1 The Society publishes “Weldability Confirmation Records” including the following (1) through (10) for rolled steels for hull having a prescribed weldability confirmed in accordance with requirements in 1A.2 through 1A.4. (1) Name of works (2) Material grade (3) Deoxidation practice (4) Fine grain practice (5) Heat treatment (6) Thickness of test assemblies (7) Welding method (8) Manufacturer and brand of welding consumables (if necessary) (9) Welding heat input applied in the confirmation test (10) The identification number of “Particulars of Approval Conditions” for the manufacturing process of the steels 2 Among those data submitted in accordance with the requirements in 1A.2.2 and 1A.4.5 which the Society deems necessary, a seal of approval is stamped and returned to the applicant.

1A.5.2 Validity of the Confirmation Records The validity of the Confirmation Records specified in preceding 1A.5.1-1 will be maintained for the duration of approval of manufacturing procedure of the rolled steels.

Part 1 Chapter 1A

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Form 1-3

To NIPPON KAIJI KYOKAI branch （Name of branch office）

APPLICATION FOR THE WELDABILITY CONFIRMATION OF HULL STRUCTURAL ROLLED STEELS

We hereby request the weldability confirmation of rolled steels for hull described hereunder in accordance with the requirements in Section 1A, Part 1 of the Guidance for the Approval and Type Approval of Materials and Equipment for Marine Use.

1. Name of works

2. Kind of products

3. Material grade

4. Deoxidation practice

5. Fine grain practice

6. Heat treatment

7. Thickness of test assemblies

8. Welding method

9. Miscellaneous

10. The identification number of “Particulars of Approval Conditions” for the manufacturing process of thesteels（No required in case that this confirmation is on time with approval of manufacturing process）

11. Date for making test assemblies

12. Date for the confirmation test

13. Submitted documents (a)Confirmation test plan 3 copies (b)Technical data 3 copies

(Signature: )


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Chapter 2 APPROVAL OF MANUFACTURING PROCESS OF STEEL PIPES

2.1 General

2.1.1 Scope 1 In accordance with the requirements in 1.2, Part K of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”), the requirements in this Chapter apply to tests inspection for the approval of manufacturing process of steel pipes (Including header. The same holds true for the remainder of this chapter.) as specified in Chapter 4, Part K of the Rules. 2 Of those materials required to be approved by the Society under the requirements in 1.1.1-2, Part K of the Rules, the requirements of this chapter correspondingly apply to the tests and inspection for the approval of the manufacturing process of steel pipes.


2.2.1 Approval Application Form Manufacturers who applies for approval of the manufacturing process of steel pipes are to submit a single copy of the Approval Application Form (see Form 1-4) filled in with required data and information to the Society.

2.2.2 Data to be Submitted 1 Three copies each of the drawings and documents given in (1) through (8) are to be submitted together with the Approval Application Form specified in 2.2.1. (1) Approval test plan (2) Data on outline of manufacturing plant (3) Data on major manufacturing facilities (4) Data on manufacturing process (5) Data on system of codes and standards (6) Data on quality control system (7) Data on mechanical properties and weldability (8) Other data deemed necessary by the Society 2 Notwithstanding the requirements in preceding -1, for materials having other grades material marks, deoxidation practice etc., and for which approval, of manufacturing process has already been granted by the Society such that data submitted at that time is duplicated by the previous data, part or all the data may be exempted from submission except for test plan for approval of the manufacturing process. 3 Where part of the manufacturing process is shared by other companies or other manufacturing plants, documents related to the manufacturing process showing the names and addresses of the other companies and plants together with the organization and method of inspection for purchasing semi-final products are to be included.


2.3.1 Approval of Test Plan The Society examines the test plan for approval submitted in accordance with the requirements in 2.2.2-1, and where deemed appropriate, the plan is approved and returned to the manufacturer.

2.3.2 Confirmation of Manufacturing and Quality Control Procedure 1 The Society may carry out surveys of the actual situation of the manufacturing plant on the basis of the data submitted according to 2.2.2-1(2), (3), (4), (5) and (6), as deemed necessary. In this case, the manufacturer is to provide the necessary information related to this survey. 2 The time of the survey, in accordance with the preceding -1, is to correspond, as a rude, to either the time of

Part 1 Chapter 2

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manufacturing of the steel pipes or the time when the approval test is carried out.

2.4 Approval Test

2.4.1 Selection of Test Samples 1 The test samples used for the approval test are to be selected, as a rule, from the steel pipes with the conditions of material manufacturing process, pipe fabrication method and heat treatment method. 2 As a rule, the dimensions of the test sample are standardized according to the maximum manufactured outer diameter and 1/2 of this value. Furthermore, the number of test pieces is to be decided each time upon mutual consultation with the Society.

2.4.2 Details of Test 1 Items of the approval test are to be as given in Table 1.2-1. 2 The test method and evaluation criteria are to be in accordance with each of the given requirements in Chapter 4, Part K of the Rules. However, where accordance with these requirements are difficult, decisions are left to the discretion of the Society.

2.4.3 Attendance of the Society’s Surveyor for Test As a rule, the Society’s Surveyor is to be present when the test samples for the approved test are being identified and when the approved test is being carried out.

2.4.4 Test Records 1 After completion of the approval test, the manufacturer is to produce a record of the approval test and is to submit three copies to the Society upon receiving confirmation by the Society’s Surveyor. 2 The record of the approval test of the preceding -1 is to be appended with work records for the manufacturing process of semi-finished products, pipe production process and heat treatment process.


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Table 1.2-1 Approval Test Items for Steel Pipes

Notes :

(1) Approval tests for each steel pipe are to be performed each test item indicated with a mark in the table. Moreover, the application of the flattening, flanging, flaring, crushing, reverse flattening and bending tests are to be in accordance with the requirements in Chapter 4, Part K of the Rules. Also, high temperature tensile test and creep test are not applicable to Grade 1, and Grade 2 of steel pipes for pressure piping.

(2) Where steel pipes with similar strength level, pipe production method, heat treatment method etc. as steel pipes for pressure piping and low temperature service have passed tests of high grade quality, tests may be omitted for steel pipes of lower grade when deemed appropriate.

(3) Where steel pipes with similar chemical composition (carbon steel or low alloy steel), pipe manufacturing process, heat treatment method etc., as steel pipes other than those of the preceding (2) have passed tests of high strength level, tests may be omitted for steel pipes of lower strength level by considering appropriate data (i.e. requirements of chemical composition, heat treatment etc., for each steel pipe).

(4) The high temperature tensile test and creep test as specified in the table are performed for the purpose of evaluating high temperature characteristics of steel pipes, and these tests may be omitted in case appropriate technical reports are available or in case Society deems the tests unnecessary.

(5) Where the steel pipes are not specified in the Rules or the steel pipes are used in special applications, tests other than those indicated in the table (e.g. tests for welded parts) or the submission of reference data may be requested. Moreover, where low temperature toughness is considered necessary, the CTOD test is required.

Part 1 Chapter 2

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2.5 Approval

2.5.1 Notification and Announcement of Approval 1 The Society grants approval of the manufacturing process of steel pipes which have been deemed appropriate on the basis of the reports of the Surveyor and documents submitted in accordance with requirements in 2.2 through 2.4. In this case, a “Certificate of Approval” is published including the name of works, kind of steel pipes, term of validity of approval etc. and the approved content etc. is described in “Particulars of Approval Conditions”. 2 Among those data submitted in accordance with the requirements in 2.2.2 and 2.4.4 which the Society deems necessary, a seal of approval is stamped and returned to the applicant. 3 Once a year, the Society announces steel pipes which have been granted approval in the form of a table.


2.5.3 Renewal of Approval 1 In case of application for renewal of approval, the applicant is to submit a “Certificate of Approval” (original) and three copies of the data showing actual manufacturing records (chemical composition, mechanical properties, outer diameter and thickness expressed in the form of histogram or statistics) of the steel pipes within the specific period together with an application from (Form 1-5). 2 The Society conducts the factory inspection. However, the Society may omit the factory inspection when actual manufacturing records are found to be satisfactory. 3 The factory inspection specified in -2 is to be completed within the valid term of “Certificate of Approval” in principle. However, for unavoidable circumstance, the factory inspection may be completed within a period of 3 months after the valid term upon the approval by the Society. 4 The Society is to examine the data showing actual manufacturing records specified in -1 and the result of factory inspection specified in -2, and if the Society considers them appropriate, is to approve the renewal of validity. 5 In case there is no data showing actual manufacturing records of steel pipes from the previous date of renewal (in case of first renewal, the date of approval) or the Society deems necessary, the Society may renew the approval considering following (1) or (2) in addition to the result of factory inspection specified in -2. (1) Data of similar grade of products (2) Result of approval test which newly carried out in accordance with the requirements in 2.2 through 2.4

2.5.4 Changes in the Approved Content 1 In case of changes in the approved content such as those given in the following (1) through (9) are occurred, in response to the content of changes, three copies of documents corresponding to the requirements in 2.2.2 are to be submitted to the Society, in addition to one copy of “Application for Changes in the Approved Content of Manufacturing Process of Steel Pipes” and a “Certificate of Approval” (original). (1) Addition to material grades (2) Changes in the steel making process (3) Changes in the casting making process (4) Changes in the rolling process (5) Changes in the limits of outer diameter and thickness (6) Changes in the heat treatment process (7) Changes in the chemical composition, added element etc. (8) In case of a part of manufacturing process (rolling, heat treatment etc.) is assigned to other works (9) Use of semi-finished products manufactured by other works 2 Upon studying the items of changes in approved content specified in -1, the Society requests the factory inspection and approval test in accordance with the requirement in 2.4 as necessary. 3 The Society is to examine the submitted data specified in -1 and reports of factory inspection and approval test specified in -2, and if the Society considers them appropriate, is to approve the changes in the approved content. In


－26－

this case, as a rule, the validity of the “Certificate of Approval” specified in -1 is not changed.

2.5.5 Revocation of Approval In case any of the following (1) through (5) is relevant, the Society may revoke approval of the manufacturing process based on the requirements in this Chapter and give notice of the revocation to the manufacturer. The manufacturer which noticed the approval is withdrawn is to return “Certificate of Approval” and “Particulars of Approval Conditions” in question to the Society. (1) When the manufacturer does not pay the approval fees. (2) When the steel pipes, whose manufacturing process has previously been granted approval, no longer conform to

the given requirements due to amendments or implementation of conventions, law, rule and regulations. (3) In one case of following (a) through (e), when the manufacturer does not take a proper action in spite of the

Society requests the investigation and improvement etc. (a) When the unstable quality is recognized at tests or inspections (b) When the harmful defects caused by the material in the process of being worked after shipment are


changed without the permission of the Society (4) When manufacturers have not been carried out the renewal of approval according to the requirements in 2.5.3. (5) When a requests for revocation is made by the manufacturer.


2.6.1 General Steel pipes which conform to the requirements in this chapter are to be dealt with as “an approved case” in the requirements in 2.2.1-1, Part K of the Rules, unless otherwise specified by the Society.

Part 1 Chapter 2

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Form 1-4


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Form 1-5

Part 1 Chapter 3

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Chapter 3 APPROVAL OF MANUFACTURING PROCESS OF STEEL CASTINGS AND STEEL FORGINGS

3.1 General

3.1.1 Scope 1 This chapter applies to the testing and inspection for the approval of manufacturing castings and forgings (except those of Anchor and Anchor Chains), specified in the provisions of Chapter 5 and Chapter 6, Part K of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”), in accordance with the provisions of 1.2, Part K of the Rules. 2 This chapter applies also to the case where the surface of steel castings and forgings are subjected to hardening process in accordance with the provisions of 5.1.2-4 and 6.1.2-6, Part K of the Rules. 3 This chapter applies correspondingly to the testing and inspection for the approval of manufacturing process of casting and forging which being required approval by the Society in accordance with the requirements of 1.1.1-2, Part K of the Rules. 4 The requirements of this chapter correspondingly apply to tests and inspection for the approval of semi-finished products such as ingot, slab and billet for the steel forgings specified in preceding -1 through -3.

3.1.2 Works The provisions for the approval of the works are applicable when any of factories specified in items (1) through (3) below manufactures castings and forgings. (1) Factory manufacturing these products by its own manufacturing facilities (including all manufacturing

processes). (2) Factory manufacturing these products by its own manufacturing facilities (including forging machine and heat

treatment furnace, etc.) but steel ingots and blooms are to be purchased from other factories. (3) Factory given in (1) or (2) above manufacturing these products by its own manufacturing facilities (including

surface hardening treatment and heat treatment processes) using semi-finished products manufactured by others.

3.1.3 Classification of Materials The castings and forgings, to which this chapter is to be applied, are classified as shown in the Table 1.3-1.

3.2 Application Procedure

3.2.1 Application Manufacturer who applies for the approval is to submit a single copy of application form (Form 1-6) filled in with the required items to the Society (branch office concerned).

3.2.2 Data to be Submitted 1 The reference data listed in (1) through (7) below, each three copies, are to be submitted together with the application form specified in 3.2.1. (1) Approval test plan (for materials only which required approval tests) (2) Factory layout drawing (3) Description of manufacturing facilities (including inspection & testing facilities) (4) Manufacturing process flow diagram (5) Description of quality control systems and quality control standards (6) List of personnel in charge of the non-destructive testing (7) Manufacturing results for the major products. 2 In case for the manufacturing materials not being required approval tests, the records of chemical composition and mechanical properties obtained within the specific period, in the form of histogram or statistics, are to be included to the data on the major products.


－30－

3 Where any part of manufacturing process is assigned to other works, additional information relevant to the name and address of the works in question together with the organization and method of inspection for the materials of which the manufacturing process is assigned are to be included. 4 Notwithstanding the requirements in preceding -1, for materials for which approval of manufacturing process has already been granted by the Society, such that data submitted at the time is duplicated by the previous data, a part or all of the data may be exempted from submission except for test plan for approval of manufacturing process specified in -1(1).

Table 1.3-1 Kinds of Materials and Finished Products

Material classification Product classification

Carbon steel castings* (1) Component parts for hull Low-alloy steel castings (Examples : stern frames, rudder frames, rudder stocks, etc.)

Stainless steel castings (2) Component parts for Diesel engines

Castings Steel castings for low temperature services

(Examples : connecting rods, piston rods, piston crowns, cylinder covers, etc.) (3) Crankshafts

Spheroidal graphite iron castings

(4) Component parts for shafting (Examples : thrust shafts, intermediate shafts, propeller shafts, etc.)

Grey iron castings

Carbon steel forgings* (5) Component parts for power transmission gears

Low-alloy steel forgings (Examples : reduction gears, reduction gear shafts, etc.)

Stainless steel forgings (6) Component parts for steam turbines Forging

s Steel forgings for low temperature services

(Examples : turbine rotors, turbine discs, turbine blades, etc.) (7) Component parts for piping (Examples : valves, pipe fittings, etc.) (8) Component parts for cargo gears (Examples : gooseneck pins, gooseneck brackets, etc.) (9) Component parts for boilers and pressure vessels (except those for low temperature service.) (10) Component parts for ships carrying liquefied gases in bulk

Note : * The object products are to be limited to those specified in 5.1.10-1 and 6.1.10-1, Part K of the Rules.


3.3.1 Approval of Test Plan The Society examines the test plan for approval submitted in accordance with the requirements in 3.2.2, and where deemed appropriate, the plan is approved and returned to the applicant. In case where deemed appropriate upon studying the data submitted, a part of approval test may be exempted.

3.3.2 Confirmation of Manufacturing and Quality Control Procedure 1 The confirmation survey on the manufacturing and quality control procedure is to be carried out, on the basis of the data specified in 3.2.2, to verify the facilities capable of manufacturing products requested approval under stable operation with a quality equivalent. 2 The time of the survey, in accordance with the preceding -1, is to correspond to the convenient time during manufacturing, particularly for the materials required approval tests, the time of survey is to correspond to either the time of sampling or the time when approval test is carried out. 3 Where deemed necessary, running test or non-destructive test may be required. 4 Notwithstanding the requirements in preceding -1, for manufacturing who has been already approved for other kind of material, confirmation survey may be exempted if deemed appropriate upon studying the reference data submitted.

Part 1 Chapter 3

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3.4 Approval Test

3.4.1 General For the materials being required approval test, approval tests are to be carried out in accordance with the test plan approved by the Society.

3.4.2 Extent of the Approval Tests 1 Approval for manufacturing process of forgings covers approval for semi-finished products with same grade, deoxidation practice, system of constituent, steel making process and steel casting process. 2 Approval for manufacturing process of steel casting is to be in accordance with the requirement of -1.

3.4.3 Attendance of the Society’s Surveyor for Test As a rule, the Society’s Surveyor is to be present when the test samples for the approval test are being identified and when the approval test is being carried out.

3.4.4 Test Records 1 After completion of the approval test, the manufacturer is to produce records of approval test, and is to submit three copies to the Society (branch office concerned) upon receiving confirmation by the Society’s Surveyor. 2 The records of approval test mentioned in preceding -1 is to be appended with records of quality control during manufacturing test samples.

3.5 Approval

3.5.1 Notification and Announcement of Approval 1 The Society grants approval of the manufacturing process for castings and forgings which has been deemed appropriate on the basis of the reports of the Surveyor and the documents submitted in accordance with the requirements in 3.2 through 3.4.

In this case, a “Notice of Approval” is published including the approval number, approval date, approval items etc. and among those data submitted in accordance with the requirements in 3.2. and 3.4.3 which the Society deems necessary, a seal of approval is stamped and returned to the applicant. 2 Once a year, the Society announces castings and forgings which have been granted approval in the form of a table.

3.5.2 Validity of Approval Valid term of the “Certificate of Approval” specified in 3.5.1-1 will be 5 years from the date of approval. In case when the renewal of approval is carried out in accordance with the requirements in 3.5.3, valid term will be 5 years from the next day after the expiry date of the previous validity.

3.5.3 Renewal of Approval and Changes in the Approved Content 1 In case of application for renewal of approval or for changes in the approved content of “Certificate of Approval” specified in 3.5.1-1 is occurred, the applicant is to apply in accordance with the requirements of 3.2. In this case, “Certificate of Approval” (original) and the documents specified in 3.2.2 are to submit together with the application form (Form 1-7). However, the data to be submitted may be limited for reference data on the changes. 2 In case of application for renewal of approval specified in -1, three copies of data showing actual manufacturing records (chemical composition and mechanical properties expressed in the form of histogram of statistics) within the specific period are to be included. In this case, the Society conducts the factory inspection. 3 The factory inspection specified in -2 is to be completed within the valid term of “Certificate of Approval” in principle. However, for unavoidable circumstance, the factory inspection may be completed within a period of 3 months after the valid term upon the approval by the Society. 4 In case of the changes in the approved content specified in -1, Society studies the items of changes in the approved content specified in -1 and carries out factory inspection as necessary. 5 The Society examines the submitted data and reports of the factory inspection and if the Society considers them appropriate, the renewal of approval or changes in the approved content is approved. In case of the changes in the approved content, as a rule, the validity of the “Certificate of Approval” is not changed.


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3.5.4 Revocation of Approval In case any of the following (1) through (5) is relevant, the Society may revoke approval of the manufacturing process based on the requirements in this Chapter and give notice of the revocation to the manufacturer. The manufacturer which noticed the approval is withdrawn, is to return “Certificate of Approval” in question to the Society. (1) When the manufacturer does not pay the approval fees. (2) When the steel castings or steel forgings, whose manufacturing process has previously been granted approval,

no longer conform to the given requirements due to amendments or implementation of conventions, law, rule and regulations.


recognized (c) When the damages caused by the material at working condition are recognized (d) When the shortcomings are recognized on the quality system or manufacturing control system (e) When the approved content described on the “Certificate of Approval” specified in 3.5.1-1 were changed

without the permission of the Society (4) When manufacturers have not been carried out the renewal of approval according to the requirements in 3.5.3. (5) When a request for revocation is made by the manufacturer.


3.6.1 General Castings and forgings which conform to the requirements of this chapter may be dealt with as “where otherwise specified or agreed with the Surveyor” in the requirements in 2.2.1-1, Part K of the Rules, unless the Society gives additional instructions.

Part 1 Chapter 3

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Form 1-6


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Form 1-7

Part 1 Chapter 4

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Chapter 4 APPROVAL OF MANUFACTURING PROCESS OF CRANKSHAFTS UNDER SPECIAL REQUIREMENTS

4.1 General

4.1.1 Scope The requirements of this chapter apply to the tests and inspection carried out for the approval of reduction for crankshafts dimensions in accordance with the requirements of 2.3.1-1 of Part D, 5.1.13-2 and 6.1.13-3 of Part K of the Rules for the Survey and Construction of Steel Ships (hereinafter referred as “the Rules”) in case where the manufacturing processes specified in the following (1) or (2) are employed: (1) The special forging processors, namely continuous grain forging method (e.g. RR forging, TR forging or stamp

forging), other than the free forging methods (block forging, upset & twisting forging and upsetting forging) used for manufacture of solid crankshafts and block forging method used for manufacture of semi-builtup crankshafts.

(2) The manufacturing processes using the surface treatments such as induction hardening, cold-rolling and nitriding.

4.2 Application Procedures

4.2.1 Application Procedures The manufacturer who applies for an approval for the manufacturing process is to submit an application together with the data showing the details of surface treatment in the case of 4.1.1(2).

4.3 Confirmation of Manufacturing and Quality Control Procedures

4.3.1 Confirmation Survey The confirmation survey of manufacturing and quality control procedures is to be carried out in accordance with the requirements of 3.3.2-1 correspondingly.

4.4 Approval Tests

4.4.1 Kinds of Steel The tests to be carried out for each kind of steels as a standard practice. Even within the category of steel forgings, normalized steels (including annealed steels or annealed steels after normalization) and quenched and tempered steels are to be considered different kind of steels. However, for example, in case where approval for carbon steel forgings in both KSF 50 and KSF 60 is applied, tests on KSF 60 which has a higher tensile strength are to be carried out as the standard procedure.

The same principle is to apply in dealing with Cr-Mo steel forgings and Ni-Cr-Mo steel forgings.

4.4.2 Approval Test for Special Forged Crankshafts (1) Test specimens

The test specimen, as standard, is to have a crankthrow with the maximum diameter of manufacture or close thereto.

(2) Tests The following items of tests are to be carried out on the test specimens: (a) Sulphur print test and macro-structure analysis (The specimens are to be taken from sections A-A, B-B and

C-C specified in Fig. 1.4-1) (b) Chemical composition analysis test (The specimens are to be taken from the positions asterisked in Fig.

1.4-1)


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(c) Micro-structure analysis (The specimens are to be taken from the positions asterisked in Fig. 1.4-1) (d) Microscopic testing method for the non-metallic inclusions (as per JIS G 0555)(The specimens are to be

taken from the positions asterisked in Fig. 1.4-1) (e) Hardness test (Positions in the vicinity of pin or journal surface. In the case of quenched and tempered

steels, hardness distribution from the surface to the shaft centre) (f) Tensile test and bend test (or impact test)(Test specimens are to be taken as specified in Fig. 1.4-2 as the

standard) (g) Bending fatigue test on actual crank throw.

The number of test specimens is to be at least 2. (h) Rotational bending fatigue test on small-size test specimens (Dia. 10～20 mm)

The number of test specimens is to be not less than 10 as the standard. In case where previous data on this test is available. Further, in the case of carbon steel forgings, this test may be omitted after obtaining an approval from the Society. (Fig. 1.4-3)

(3) Judgement of test results The manufacturing process can be approved in case where the results of tests of the preceding (2) proves that the special forged crankshaft continuous grain flow, the product quality is judged stable and the fatigue strength obtained from (2)(g) have improved by 20% or more when compared with the fatigue strength of a free-forged crankshaft Wσ (N/mm2) calculated by the following formula :

When D≤ 100,

⎥⎦

⎤⎢⎣

⎡⎟⎠

⎞⎜⎝

⎛−+= 1

440321196 S

WT

σ

When 100<D<200,

⎥⎦

⎤⎢⎣

⎡⎟⎠

⎞⎜⎝

⎛−+⎟

⎠⎞

⎜⎝⎛ −= 1

440321

1.5216 S

WTDσ

When D≥ 200,

⎥⎦

⎤⎢⎣

⎡⎟⎠

⎞⎜⎝

⎛−+= 1

440321177 S

WT

σ

D : diameter of test specimen (mm) ST : specified minimum tensile strength (N/mm2)

Fig. 1.4-1 Sampling Positions

Part 1 Chapter 4

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Fig. 1.4-2 Sampling Positions of Test Specimens

Fig. 1.4-3 Sampling Positions of Bend Test Specimens

4.4.3 Approval Test for Crankshafts with Surface Treatments This requirement applies to cases where the fillets of a crankshaft are applied with induction hardening, cold-rolling or nitriding, etc. In case where surface treatment is applied to all over crankpin, journal and fillets, consideration will be given for testing procedure in each case. (1) Test specimens

The requirements specified in 4.4.2(1) apply correspondingly. (2) Tests

The following tests are to be carried out on test specimens: (a) Non-destructive testing (The conditions of defects on surface of the test specimens before and after the

surface treatment are to be examined. The detection is to be either by magnetic particle test or liquid penetrant test.)

(b) Examination of the hardness distribution, depth of hardening and residual stress (Examination is to be carried out on the surface treated areas and their vicinity. Further, in case where cold-rolling is carried out, measurements for the deformation on the cold-rolling area are to be included.)


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(c) Surfer print test, microstructure test and macroscopic test (to be carried out on the sectional area in the direction of hardening depth.)

(d) Bending fatigue test on actual crank throw (Tests are, in principle, to be carried out on both the crank throws with and without surface treatments. In this case, the number of test specimens are to be sufficient to verify the strength improvement ratio ρ specified in 2.3.1-1, Part D of the Rules. In this connection, the

torsional fatigue tests on the actual crank throws or the test specimens having sizes similar to them are also to be carried out.)

(e) Tensile test and bend test (or impact test)(one set of test specimens as to be taken from end portion of crankshaft with surface treatment.)

(3) Judgement of test results The manufacturing process can be approved in case when the results of tests of preceding item (2) prove that a stability in the quality of the crankshafts with surface treatment and excellent improvement in the fatigue strength are obtained.

4.4.4 Approval for Special Forged Crankshafts with Surface Treatment In case where the crankshaft manufactured under the special process as specified in the preceding 4.1.1(1) is applied with the surface treatment as specified in 4.1.1(2), the judgement for acceptance is to be determined by considering the results of tests for free forged crankshaft with surface and the strength of other positions of the crankshaft than the fillets thereof.

4.5 Notification of Approval

4.5.1 Notification of Approval Where the results of the approval test specified in 4.4 are examined and considered satisfactory, the Society approves the manufacturing process on the crankshaft and gives a notification of approval to the applicant.

4.6 Periodical Survey for Continuation of Approval

4.6.1 Periodical survey The periodical survey for continuation of the approval is to be carried out in accordance with the requirements of 3.5.3.

Part 1 Chapter 5

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Chapter 5 APPROVAL OF MANUFACTURING PROCESS OF ALUMINIUM ALLOYS

5.1 General

5.1.1 Scope 1 In accordance with the requirements in 1.2, Part K of the Rules for the Survey and Construction of Steel Ships (hereinafter referred as “the Rules”), the requirements in this chapter apply to tests and inspection for the approval of manufacturing process of aluminium alloys as specified in Chapter 8, Part K of the Rules. 2 Of those materials required to be approved by the Society under the requirements in 1.1.1-2, Part K of the Rules, the requirements of this chapter correspondingly apply to the tests and inspection for the approval of the manufacturing process of aluminium alloys.


5.2.1 Approval Application Form Manufactures who applies for approval of the manufacturing process of aluminium alloys are to submit a single copy of the Approval Application Form (Specimen Form 1-1) filled in with required data and information to the Society.

5.2.2 Data to be submitted 1 Three copies each of the drawings and documents given in (1) through (8) are to be submitted together with the Approval Application Form specified in 1.2.1. (1) Approval test plan (2) Data on outline of manufacturing plant (3) Data on major manufacturing facilities (4) Data on manufacturing process (5) Data on system of codes and standards (6) Data on quality control system (7) Data on mechanical properties and weldability (8) Other data deemed necessary by the Society 2 For aluminium alloys specified in Table K8.3(a), Part K of the Rules, in the H116 and H321 tempers intended for use in marine hull construction or in marine applications where frequent direct contact with seawater is expected, the manufacturer is to submit the documents which exhibits the relationship between microstructure and resistance to corrosion in addition to the requirements in preceding -1. This documents is to include a reference photomicrograph (approx. 500x) intended for use in metallographic examination as specified in 8.1.8, Part K of the Rules. A reference photomicrograph are to be taken for each of the alloy-tempers and thickness ranges relevant from samples which have passed the corrosion test as specified in K8.1.8(2), Part K of the Guidance for the Survey and Construction of Steel Ships. 3 Notwithstanding the requirements in preceding -1 and -2, for materials having other grades material marks, heat treatment etc., and for which approval of manufacturing process has already been granted by the Society such that data submitted at the time is duplicated by the previous data, part or all of the data may be exempted from submission except for test plan for approval of the manufacturing process. 4 Where part of the manufacturing process is shared by other companies or other manufacturing plants, documents related to the manufacturing process showing the names and addresses of the other companies and plants together with the organization and method of inspection for purchasing semi-final products are to be included.


－40－


5.3.1 Approval of Test Plan The Society examines the test plan for approval submitted in accordance with the requirements in 5.2.2-1, and where deemed appropriate, the plan is approved and returned to the manufacture.

5.3.2 Confirmation of Manufacturing and Quality Control Procedure 1 The Society may carry out surveys of the actual situation of the manufacturing plant on the basis of the data submitted according to 5.2.2-1(2) through (6) as deemed necessary. In this case, the manufacturer is to provide the necessary information related to this survey. 2 The time of survey, in accordance with the preceding -1, is to correspond, as a rules, to either the time of rolling and extruding of aluminium alloys or the time when the approval test is carried out.

5.4 Approval Test

5.4.1 Selection of Test Samples The test sample used for the approval test are to be selected from the parts of the aluminium material produced, as a rule, from the top and bottom portions of the ingot.

5.4.2 Details of Test 1 The plate thickness and dimensions for the test sample used in the approval test are, as a rule, to be the maximum manufactured thickness and dimensions. 2 The approval test items, method and evaluation criteria of the approval test are to be as given in Table 1.5-1 and Table 1.5-2 respectively.

5.4.3 Attendance of the Society’s Survey or for Test As a rule, the Society’s Surveyor is to be present when the test samples for the approval test are being identified and when the approval test is being carried out.

5.4.4 Test Records 1 After completion of the approval test, the manufacturer is to produce a record of the approval test and is to submit three copies to the Society upon receiving confirmation by the Society’s Surveyor. 2 The records of the approval test of the preceding -1 is to be appended with work records relating to melting, ingot-making, rolling (extruded shape forming) and heat treatment of the test samples.

Part 1 Chapter 5

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Table 1.5-1 Approval Test Items for Aluminium Alloys Kind of Test(1), (2)

Products

Material grade

Temper grade

Chem

ical analysis

Macrostructure

Microstructure

Tensile test at room

temperature

Tensile test at low

temperature

(3)

Tensile test of notched round bar (3)

Tensile test in the direction of thickness (4)

Bend test

Tear test (3)(5)

Corrosion test (6)

O H111

5083P H112 H116 H321 O H111

5086P H112 H116 H321 O

5383P H111 H116 H321 O

5059P H111 H116 H321

5754P O H111 O

5456P H116 H321

Rolled Products

6061P T6 O

5083S H111 H112 O

5086S H111 H112 O

5383S H111 H112

5059S H112 6005AS T5

T6 6061S T5

T6 6082S T5

Extruded shapes

T6


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(Note) (1) Each test item indicated with a mark in the Table are to be performed for approval tests for each aluminium

alloys. (2) When deemed necessary by the Society, tests related to fatigue tests, weld joint tests, corrosion resistance tests, stress

corrosion cracking tests etc., or submission of reference data relating to these tests are requested. (3) This test is carried out for aluminium alloys used at extremely low temperature such as tanks for liquefied gas

carrier. (4) This test is carried out for test sample with thickness more than 100mm. (5) Other tests may be applied, subject to the approval by the Society. (6) This test is carried out for aluminium alloys intended for use in marine hull construction or in marine applications

where frequent direct contact with seawater is expected.

Table 1.5-2 Approval Testing Method and Acceptance Criteria Approval test

items Selection of test

specimen Testing method Acceptance criteria

Location Direction(1) Chemical analysis T

(Top Part) JIS H 1305, H 1306 or equivalent

method. Chemical composition by ladle analysis is to comply with the

B (Bottom Part)

Ladle analysis and product analysis are to be performed.

Requirements in Chapter 8, Part K of the Rules(2)

Macro-structure T - To be as deemed appropriate by To be as deemed appropriate by B the Society. The Society. Micro-structure T - B Tensile test at T Parallel In accordance with Chemical composition by ladle room temperature Transverse Part K of the Rules. analysis is to comply with the B Parallel requirements in Transverse Chapter 8, Part K of the Rules. Tensile test at T Parallel The tensile tests are to be carried To be as deemed appropriate by low temperature B Transverse out at -196 by using of the the Society. T Parallel tensile test specimens of the same B Transverse size and the room temperature. Tensile test of notched round bar

T Parallel The tensile tests are to be carried out at -196 by using of the

Transverse tensile test specimens of notch; B Parallel Angle of notch : 60°

Root radius of notch: 0.05mm

Transverse or less Tensile test in the direction of

T Direction of thickness

The test specimens are to be selected in the direction of thickness,

thickness B Direction of thickness

and tensile tests are to be carried out.

Bend test T Parallel To be as deemed appropriate by No crack is to be accepted. Transverse the Society. B Parallel Transverse Tear test T Transverse Tear strength and crack propagation

energy are to be determined. To be as deemed appropriate by the Society.

B Transverse Size and dimensions of tear test specimens are to be as deemed appropriate by the Society.

Corrosion test T B

Parallel ASTM G 66, G 67 or equivalent method.

To be as deemed appropriate by the Society. (3)

Part 1 Chapter 5

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Note : (1) When the test specimens used for the approval test can not be taken from the test samples because of their

dimensions or shapes, the direction of the selection of the specimens to be determined on a case-by-case basis upon mutual consultation by the manufacturer and the Society.

(2) Excess difference in the chemical composition between ladle analysis and product analysis is not to be accepted. (3) When subjected to the test described in ASTM G 66, the samples are to have exhibited no evidence of exfoliation

corrosion and a pitting rating of N, PA or PB. When subjected to the test described in ASTM G 67, the samples are to have exhibited resistance to intergranular corrosion at a mass loss no greater than 15 mg/cm2.

5.5 Approval

5.5.1 Notification and Announcement of Approval 1 The Society grants approval of the manufacturing process of aluminium alloys which have been deemed appropriate on the basis of the reports of the Surveyor and documents submitted in accordance with requirements in 5.2 through 5.4. In this case, a “Certificate of Approval” is published including the name of works, kind of aluminium alloys, term of validity of approval etc. and the approved content etc. is described in “Particulars of Approval Conditions”. 2 Among those data submitted in accordance with the requirements in 5.2.2 and 5.4.4 which the Society deems necessary, a seal of approval is stamped and returned to the applicant. 3 Once a year, the Society announces aluminium alloys which have been granted approval in the form of a table.


5.5.3 Renewal of Approval 1 In case of application for renewal of approval, the applicant is to submit a “Certificate of Approval” (original) and three copies of the data showing actual manufacturing records (chemical composition, mechanical properties for each grade and thickness expressed in the form of histogram or statistics) of the aluminium alloys within the specific period together with a application form (Form 1-2). 2 The Society conducts the factory inspection. However, the Society may omit the factory inspection when actual manufacturing records are found to be satisfactory. 3 The factory inspection specified in -2 is to be completed within the valid term of “Certificate of Approval” in principle. However, for unavoidable circumstance, the factory inspection may be completed within a period of 3 months after the valid term upon the approval by the Society. 4 The Society is to examine the data showing actual manufacturing records specified in -1 and the result of factory inspection specified in -2, and if the Society considers them appropriate, is to approve the renewal of validity. 5 In case there is no data showing actual manufacturing records of aluminium alloys from the previous date of renewal (in case of first renewal, the date of approval) or the Society deems necessary, the Society may renew the approval considering following (1) or (2) in addition to the result of factory inspection specified in -2. (1) Data of similar grade products (2) Result of approval test which newly carried out in accordance with the requirements in 5.2 through 5.4

5.5.4 Changes in the Approved Content 1 In case of changes in the approved content such as those given in the following (1) through (9) is occurred, in response to the content of changes, three copies of documents corresponding to the requirements in 5.2.2 are to be submitted to the Society, in addition to one copy of “Application for Changes in the Approved Content of Manufacturing Process of Aluminium Alloys” and a “Certificate of Approval” (original). (1) Addition to material grades (2) Changes in the steel making process (3) Changes in the casting making process


－44－

(4) Changes in the rolling process or extrusion process (5) Changes in the limits of thickness or dimension (6) Changes in the heat treatment process (7) Changes in the chemical composition, added element etc. (8) In case of a part of manufacturing process (rolling, extrusion, heat treatment etc.) is assigned to other works (9) Use of semi-finished products (slabs, blooms and billets etc.) manufactured by other works 2 Upon studying the items of changes in approved content specified in -1, the Society requests the factory inspection and approval test in accordance with the requirements in 5.4 as necessary. 3 The Society is to examine the submitted data specified in -1 and reports of factory inspection and approval test specified in -2, and if the Society considers them appropriate, is to approve the changes in the approved content. In this case, as a rule, the validity of the “Certificate of Approval” specified in -1 is not changed.

5.5.5 Revocation of Approval In case any of the following (1) through (5) is relevant, the Society may revoke approval of the manufacturing process based on the requirements in this Chapter and give notice of the revocation to the manufacturer. The manufacturer which noticed the approval is withdrawn is to return “Certificate of Approval” and “Particulars of Approval Conditions” in question to the Society. (1) When the manufacturer does not pay the approval fees. (2) When the alminium alloys, whose manufacturing process has previously been granted approval, no longer

conform to the given requirements due to amendments or implementation of conventions, law, rule and regulations.



changed without the permission of the Society (4) When manufacturers have not been carried out the renewal of approval according to the requirements in 5.5.3. (5) When a request for revocation is made by the manufacturer.


5.6.1 General Aluminium alloys being confirmed to meet the requirements of this chapter are to be dealt with as “an approved case” in the requirements in 2.2.1-1, Part K of the Rules, unless otherwise specified by the Society.

Part 1 Chapter 6

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Chapter 6 APPROVAL OF MANUFACTURING PROCESS OF PROPELLER CASTINGS

6.1 General

6.1.1 Scope 1 The requirements of this chapter apply to the tests and inspection for the approval of the manufacturing process of propeller castings manufactured with the materials specified in Chapter 5 and 7, Part K of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”) in accordance with the requirements of 1.2, Part K of the Rules. 2 Among the materials required to be approved by the Society in accordance with the requirements of 1.1.1-2, Part K of the Rules, the tests and inspection for the approval of the manufacturing process of propeller castings are to be in accordance with the requirements of this Chapter.


6.2.1 Application Form Manufacturer who applies for the approval of the manufacturing process of propeller casting in accordance with this chapter is to submit an approval application form filled in with material grade, type of propeller and maximum diameter of manufacturing propeller to the Society (branch office concerned).

6.2.2 Data to be Submitted 1 Three copies each of the documents given in (1) through (6) are to be submitted together with the approval application form specified in 6.2.1. (1) Approval test plan (2) Data on outline of works (3) Data on major manufacturing facilities (molding, melting, casting, furnace and machining installation and their

capacity) (4) Data on manufacturing process (5) Data on quality control system (6) List of the person of engaged in non-destructive test 2 Where any part of manufacturing process is assigned to other works, documents relevant to the name and address of the other works in question together with the organization and method of inspection for the materials of which the manufacturing process is assigned are to be included. 3 Notwithstanding the requirements in preceding -1, where the documents are duplicated by the ones previous approval for the same type of product, part or all of the documents may be omitted except for test plan for approval of manufacturing process specified in -1(1).


The preliminary examination is to be carried out in accordance with the requirements 3.3.

6.4 Approval Test

6.4.1 Details of Test 1 As an approval test, property test is to be carried out. The test items are, in principle, to be as follows : (1) Analysis of chemical composition :

Analysis of chemical composition on ladles and separately cast are to be carried out. (2) Tensile test :


－46－

Tensile tests are to be carried out on the propeller castings and separately cast. Three each of test specimens from the propeller castings are to be taken from the position in the proximity of 0.2-0.35R (R is radius of the propeller) and the position in the section with maximum blade thickness.

(3) Micro-structure analysis : Micro-structure analysis is to be made on each tensile test specimen.

(4) Macro-structure analysis : Macro-structure analysis is to be made on the blade section in the proximity of 0.2-0.35R.

(5) Other test items which are deemed necessary by the Society. 2 Notwithstanding the requirements of the preceding -1, some part of the property test may be omitted in case of propellers with a diameter of 2.5m or less.

6.4.2 Attendance of the Society’s Surveyor for Test Attendance of the Society’s surveyor for test is to be carried out in accordance with the requirements 3.4.2.

6.4.3 Test Records Test record is to be submitted in accordance with the requirements 3.4.3.

6.5 Approval

Approval of manufacturing process of propeller castings is to be carried out in accordance with the requirements 3.5.

Part 2 Chapter 1

－47－

Part 2 EQUIPMENT

Chapter 1 APPROVAL OF MANUFACTURING PROCESS OF ANCHORS

1.1 General

1.1.1 Scope 1 This chapter applies to the procedures and testing requirements for the approval of the manufacturing process of anchors in accordance with the requirements in 2.1.4, Part L of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”). 2 Of those equipment required to be approved by the Society under the requirements in 1.1.1-2, Part L of the Rules, the requirements of this chapter correspondingly apply to the tests and inspection for the approval of the manufacturing process of anchors.


1.2.1 Application Procedures and Application Form 1 Manufacturer who intends to obtain approval is to submit a single copy of application form (See Form 2-1) filled with the following items of information accompanied by the reference data, each in triplicate, stated in 1.2.2 to the Society. (1) Kind and type of the anchor to be approved (2) Maximum mass of the anchor to be approved 2 The Society examines the application for approval and the attached reference data stated in the above and where deemed appropriate, the “Approval test plan” is approved and returned to the applicant.

1.2.2 Reference Data to be Submitted The reference data on items shown below are to be attached to the application for approval. (1) The drawing which includes dimension table for each size of anchor (2) Outline of manufacturing plant (3) Facilities, technical staffs and organization for anchor manufacturing (4) Working standards for casting and heat treatments (to be accompanied by drawings) (5) Inspection and testing facilities (6) Non-destructive testing standards (7) Approval test plan (8) Test data of sea bed holding power and information concerning the anchor

1.2.3 Omission of Reference Data The submission of the data may be omitted in case where the anchor under application is manufactured at the same facilities as used for other anchor on which an approval of the Society was given previously with a manufacturing process considered by the Society nearly identical to the process and control system already approved.

1.3 Confirmation of Manufacturing and Quality Control Procedure

1.3.1 Confirmation Survey of Manufacturing and Quality Control Procedure The confirmation survey is to be carried out in order to confirm that the manufacturer is capable of manufacturing anchors under the informed condition (manufacturing facilities, technical capacity, organizations for quality control and test and inspection system) at the stable quality on a continuous basis, and at the same time, is to practically verify that anchors will be manufactured in the future under the same manufacturing process as applied for


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approval.

1.3.2 Omission of Confirmation Survey Where application is placed for extending the scope of approval on anchors to be manufactured in the identical manufacturing plant under almost the same manufacturing process with the case of the anchor already approved in the past, only the examination of the technical documents is to be made and the confirmation survey may be omitted.

1.3.3 Investigation Items of Confirmation Survey The following items are to be examined in the confirmation survey : (1) Inspection organization and claim handing system (2) Manufacturing and inspection facilities (3) Status of quality control system

1.4 Approval Test

1.4.1 Test Requirements The approval test is to be carried out on an anchor with the mass closest to the maximum applied mass on the following item, in the presence of the Surveyor of the Society. (1) Material test (test specimens are to, in principle, be taken from the body and the test blocks attached thereto). (2) Proof test (3) Drop test (dropping is to be made for least 3 attempts.) (4) Hammering test (5) Visual inspection (6) Non-destructive test (radiographic or ultrasonic test for internals, visual inspection or magnetic particle flaw

detection for external.)

1.4.2 Submission of Test Records The manufacturer is to submit the approval test report and work records of the manufacturing process on the test anchor (steel marking process, casting process, heat treatments, etc.), in triplicate, endorsed by the attended surveyor.


The Society upon finding that the results of the confirmation survey and the records of approval tests are all satisfactory, is to approve the manufacturing process of the anchor, and send a notice of approval to the applicant.

1.6 Approval of Manufacturing Process of High Holding Power Anchors

1.6.1 High Holding Power Anchors The approval procedure for manufacturing of high holding power anchor (the anchor specified in 2.1.4-2, Part L of the Rules, having the holding power two times or more of that of ordinary anchor, and if it is used without subjected to the reduction as specified in 27.1.3-3, Part C of the Rules, such anchor may not be dealt with as a high holding power anchor), is to be as follows in addition to the requirements specified in 1.2 through 1.5 of this chapter. (1) Application for approval

An application for approval (sample of the application form is given in Form 2-2) stating the following items is to be submitted to the Society. (a) Kind and type of the anchor (b) Maximum mass of the anchor

(2) Test plan The manufacturer is to prepare a testing plan on items given in (3) and (4) below and submit it to the Society.

(3) Holding Power Test (a) The anchors for testing are to be two anchors having different mass (One is an anchor having a mass

equivalent to 1/10 of the maximum mass to be approved or more and the other is an anchor having a mass equivalent to 1/10 of mass of that anchor or more.) and two anchors for comparison having a mass equivalent to that of the test anchors.

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(b) The holding power measuring test is to be carried out in three of the soil (sand, silt and clay) three times on each test anchor and once on each anchor for comparison where the anchors are to be dragged at a fixed speed (as slow as practicable). The sea bed for testing is to be of virgin bed for each attempt of testing. However, the number of test attempts may be increased/decreased as considered necessary or appropriate by the Society.

(c) Where sufficient data is submitted, and if the Society considers it appropriate, all or parts of the holding power measuring test may be omitted.

(4) Embed Test, etc. Where deemed necessary by the Society, the test to verify the stability of the anchor and the embed test are to be carried out.

(5) Submission of test reports The manufacturer, on completion of the tests, is to prepare test records, in triplicate, covering, at least, the following items in addition to those given in 1.4.2, obtain the signature of the attended surveyor of the Society, and to submit them to the Society. (a) Testing procedure and test arrangement (explanatory drawings on the testing procedure and test

arrangement are to be attached thereto.) (b) The results of holding power measuring test (in addition to the results of holding power measuring test

(Hp/W = Holding Power/Weight), holding power characteristics curves are to be attached thereto.) (c) Properties of the soil of the sea bed (hardness, composition) and flatness of the sea bed (d) The dragging speed of the anchor in the holding power measuring test (e) The test results, where the tests specified in 1.6.1(3)(c) are carried out

1.7 Approval of Manufacturing Process of Super High Holding Power Anchors

1.7.1 Super High Holding Power Anchor The approval procedure for manufacturing of super high holding power anchor (the anchor specified in 2.1.4-2, Part L of the Rules, having the holding power four times or more that of ordinary anchor. If it is used without the reduction of mass as specified in 27.1.3-4, Part C of the Rules, such anchor may not be dealt with as a super high holding power anchor), is to follow the requirements in 1.2 through 1.6 of this chapter. However, the anchor for holding test specified in 1.6 are to be two test anchors having different mass (One is an anchor having a mass equivalent to, 1/5 of the maximum mass to be approved or more and the other is an anchor having a mass equivalent to 1/5 of mass of that anchor or more.) and two anchors for comparison having a mass equivalent to that of the test anchors. Any approved high holding power anchor may be used in place of an ordinary anchor.


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Form 2-1 Application for Approval of Anchor Manufacturing Process (Example)

Part 2 Chapter 1

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Form 2-2 Application for Approval of High Holding Power Anchor or Super High Holding Power Anchor Manufacturing Process (Example)


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Chapter 2 APPROVAL OF MANUFACTURING PROCESS OF CHAINS

2.1 General

2.1.1 Scope 1 The procedures and testing requirements for the approval of the manufacturing process of anchor chains, steering chains and offshore chains including a connecting common links which are manufactured by flash butt welding or casting in accordance with the requirements in 3.1.4 and 3.2.5, Part L of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”) are to be as specified in this Chapter. 2 The procedures and testing requirements for the approval of the manufacturing connecting common links are separately applied to those of offshore chains. 3 Of those equipment required to be approved by the Society under the requirements in 1.1.1-2, Part L of the Rules, the requirements of this Chapter correspondingly apply to the tests and inspections for the approval of the manufacturing process of chains. 4 For the chains manufactured by forge welding or other methods, the procedures of testings and inspections apply to the requirements of this Chapter correspondingly. 5 Manufactures who manufacture the casting chain according to apply the requirements of -1 above, the procedures of manufacturing castings have been considered to be obtained to the approval of the Society based upon the requirements of 1.2, Part K of the Rules.


2.2.1 Application Procedures and Application Form The approval application procedures are to be in accordance with the following requirements: (1) The manufacturer who intends to newly manufacture chains is to submit a single copy of application form (see

Form 2-3) filled with the information on the type of chains accompanied by the reference data, each in triplicate, stated in 2.2.2 to the Society.

(2) The Society, upon examining the application for approval and the attached reference data stated in the above, is to give approval of the test procedure for approval and return them to the applicant.

2.2.2 Reference Data to be Submitted 1 The reference data to be attached to the application for approval and to test procedure for the approval of the manufacturing process are to cover the items shown below: (1) Flash butt welded chains

(a) Manufacturing process and manufacturing facilities i) Explanations on manufacturing process ii) Outline of the manufacturing factory iii) Principal items of manufacturing inspection facilities other than welding machines (tensile testing

machine of chains, furnace for heat treatment, preheater, bending machine, stud applier etc.) (b) Welding machines

i) Name and type welding machine, and name of his manufacture ii) Particulars of welding machine (output, pressurizing force, retaining force) iii) Pressurizing mechanism (drawing are to be attached) iv) Diameter of chain link weldable

(c) Working standards i) Inspection organization chart ii) Contents of inspection at the reception of raw materials iii) Working standards applicable to each size of chain link for cutting raw materials, heating, bending and

folding, flash butt welding (welding conditions, flash allowance, upsetting allowance, preheating

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temperature and period), post-welding removal of burrs, applications process of studs, etc. iv) Stud manufacturing process and dimensions v) Stud welding standards vi) Procedures of heat treatments and their control standards (For offshore chains, standards of heat

treatment and standards between temperature of chains and chain speed to obtained specific mechanical properties are to include)

vii) Details of product inspection viii) Repairing procedures

(2) Cast chains (a) Manufacturing process and manufacturing facilities

i) Explanations on manufacturing process ii) Outline of the manufacturing factory iii) Principal manufacturing and inspection facilities

(b) Steelmaking i) Type and capacity of steelmaking furnace ii) Steelmaking process iii) Range of chemical composition

(c) Work standards i) Moulding work ii) Casting procedure (drawing showing the location and its dimensions of riser to be attached) iii) Procedure of heat treatment and its control standards iv) Finishing work v) Details of product inspection (proof test, breaking test, mechanical test and non-destructive test are

included) vi) Repairing procedures

2 Notwithstanding the requirements in -1 above, submission of part or all of the reference data may be omitted if the manufacturer had previous record of obtaining the approval of the Society in the past, and the duplicated data are included therein.


2.3.1 Confirmation Survey of Manufacturing and Quality Control Procedure The confirmation survey is to be carried out in order to confirm the manufacturer of chains is capable of manufacturing products by the manufacturing process under application at the stable quality on a continuous basis.

2.3.2 Items of Confirmation Survey The confirmation survey is to be carried out for each lot of chain applied or for each manufacturing factory on the following items: (1) Status of manufacturing facilities of the factory, manufacturing ability, and current status of inspection facilities (2) Status of product quality control and inspection department (3) Establishment of various working standards and the status of execution of such standards.

2.3.3 Execution of Confirmation Survey The time of confirmation survey is to, in principle, be such time when the chains under application are being manufactured or when the approval test is carried out.

2.3.4 Omission of Confirmations Survey When the chains are manufactured by the same manufacturing facilities wherein the previously approved chains were manufactured under nearly compatible manufacturing process, the confirmation survey may be omitted.


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2.4 Approval Test

2.4.1 Approval Test The approval test is to be carried out on each chain under application for each manufacturing factory. The contents of the approval test are to be as indicated in Table 2.2-1 and the test is to be carried out in the presence of the Surveyor of the Society unless otherwise specified.

2.4.2 Test Chains The link and test specimens used in the approval test are to be taken from the test chains in the presence of the Surveyor of the Society.

2.4.3 Omission of Approval Test for Manufacturing Process (1) When the test for Grade 1 chains has been passed, the approval test for manufacturing process for studless

chains of the same or of the smaller diameter manufactured by the same flash butt welding method may be omitted.

(2) When the test for Grade 2 chains has been passed, the approval test for manufacturing process for studless chains of the same or of the smaller diameter manufactured by the same flash butt welding method may be omitted.

(3) The manufacturing process of the enlarged link and end link may be approved up to those with the diameter corresponding to that of common link provided that they are manufactured by the same manufacturing process of the common link or by the flash butt welding method.

Part 2 Chapter 2

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Table 2.2-1 Approval Test Items and Acceptance Criteria for Chains

Notes:

(1) The test links used in the approval test are to, in principle, be of the desired largest diameter for approval. (2) In the case of cast links, their mechanical properties tests are to be carried out in a manner corresponding to those


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applied to weld zone. Of those items of test of the testing object, the tensile test and compression test may be substituted by magnetic particles testing.

(3) Temperatures of impact test are to be in accordance with Table 2.2-2. (4) The COD test as in specified in Table 2.2-1 is performed for the purpose of evaluating low temperature toughness

characteristics, and this test may be omitted in case appropriate records prepared by the manufacturer are available and in case appropriate to the Society.

(5) In the case of the approval test in association with the change in the manufacturing process as shown in 2.7, the diameter and number of test link, or the approval test items may be reduced.

(6) When steel materials, manufacturing process or heat treatment methods which are not specified in the rules are to be employed, the Society may request other tests or submission of reference materials in addition to the specified test items.

Table 2.2-2 Temperature of Impact Test

Kind of chain Temperature Minimum absorbed average energy (J)

Base metal Weld zone

Grade 1 chain 0 To be with reference. To be with reference. Grade 2 chain

20, 0

At 0 to be of 50 J. At other temperatures to be with reference.

To be with reference.

Grade 3 chain and -20 At 0 to be of 60 J. At other temperatures to be with reference.

At 0 to be of 50 J. At other temperatures to be with reference.

Grade R3 offshore chain

At 0 to be of 60 J At -20 to be of 40 J At -40 to be with reference.


Grade R3S offshore chain

0, -20 and -40



Grade R4 offshore chain

At -20 to be of 50 J. At other temperatures to be with reference.

At -20 to be of 36 J. At other temperatures to be with reference.

2.5 Submission of Test Reports

The manufacturer, after completion of the approval test, is to prepare test reports including those covering the manufacturing process of test chains and records of heat treatments all endorsed by the Surveyor of the Society, and is to submit to the Society.


The Society is to examine the reports of approval test and the results of confirmation survey and when they are considered acceptable, the Society is to give notification to the manufacturer to that extent.

2.7 Changes in the Approval Content

2.7.1 Changes in the Approval Content When major changes are intended to be made in the manufacturing process already approved, the application procedure for a new approval application is to be taken. The major changes include the items given below where, however, the witness of the approval test by the surveyor of the Society may be dispensed with, or reduction in the approval test items may be accepted for the manufacturer whose product quality control standards and inspection standards are considered appropriate. In this case, however, submission of the results of tests on material properties and related data is required.

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(1) Increase in the maximum diameter of chain to be manufactured (2) Change in casting procedure (3) Changes in heat treatments (quenching, annealing, tempering, etc.) (4) New installation of welding machine (5) New installation of furnace for heat treatment (6) Other changes for which approval test is considered necessary by the Society

2.8 Others

2.8.1 Using of Outside Manufacturing Facilities When the manufacturer of the products including those used in the approval test of manufacturing process and subsequent manufacture in respect of the manufacture of studs, heat treatments, tensile testing of chains are sublet to other contractors, notice is to be given to the Society to that extent.

2.8.2 Revocation of Approval The approval for manufacturing process may revoked in the following cases: (1) When the records of manufacturing process and the results of various tests and inspection significantly differ

from those accepted at time of approval and do not satisfy the approved conditions. (2) When the revocation of the approval is proposed by the manufacturer under the reasons the termination of the

manufacture.


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Form 2-3 Application for Approval of Manufacturing Process of Chains (Example)

Part 2 Chapter 3

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Chapter 3 APPROVAL OF MANUFACTURING PROCESS OF CHAIN ACCESSORIES

3.1 General

3.1.1 Scope 1 The procedures for the approval of the manufacturing process and handling of the test of the connecting shackles, kenter shackles, anchor shackles and swivels (hereinafter referred to as the “chain accessories”) specified in the provisions of 3.1.4-4 and 3.2.5-4, Part L of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”) are to be in accordance with the requirements given in this Chapter. 2 The procedures for the approval of the manufacturing and handling of the test of chain accessories specified in the provisions of 1.1.1-2, Part L of the Rules are to be in accordance with the requirements in this Chapter. 3 When the enlarged link and end link are manufactured by a chain accessories manufacturer other than the manufacturer of the chain, the approval test for manufacturing process is to be arranged notwithstanding the provisions in 2.4.3(3). 4 When manufacturing method other than the casting method or forged is employed based upon the provisions of 1.2, Part K of the Rules, advance notice is to be given to the Society to this extent. 5 For other requirements than those specified this Chapter, the provisions in Chapter 2 are to apply.

3.2 Approval Application Procedures

3.2.1 Approval Application Procedures The provisions in 2.2.1 are to apply to the approval application procedures.

3.2.2 Reference Data to be Submitted The reference data to be attached to the application for the manufacturing process are to be as follows: (1) Cast chain accessories

To be in accordance with the provisions in 2.2.2-1(2) (2) Forged chain accessories

(a) Manufacturing process and facilities i) Explanations on manufacturing process ii) Outline of the manufacturing factory iii) Principal forging facilities and their capacity iv) Type and capacity of the furnace for heat treatments v) Inspection and testing facilities

(b) Work standards i) Details of acceptance inspection for raw materials (bloom, billet, round bar materials, etc.) and means

of their suppliers ii) Forging procedures and their control standards iii) Details of product inspection


3.3.1 Confirmation of Manufacturing and Quality Control Procedure The confirmation survey is to be carried out in accordance with the provisions in 2.3.


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3.4 Approval Test

3.4.1 Approval Test The approval test is to be carried out on each item of chain accessories under application for each manufacturing factory. The details of approved test are to be as indicated in Table 2.3-1, and the test is to be carried out in the presence of the Surveyor of the Society unless otherwise specified.

3.4.2 Test Chain Accessories The Specimens used in the approval test are to be taken from the test chain accessories under application in the presence of the Surveyor of the Society.

3.4.3 Omission of Approval Test (1) When the test for chain has accessories of higher grade has been passed, the approval test for manufacturing

process for chain accessories of the same or of the smaller diameter manufactured by the same casting or forging method may be omitted.

(2) When the test either for swivel or for kenter shackle has been passed, the approval test for manufacturing process for another product not subjected to approval test may be omitted provided that discrimination between the casting procedure and forging procedure is specified.

(3) When the test either for swivel or for kenter shackle has been passed, the approval test for manufacturing process for the enlarged link and end link of the same diameter as that of the swivel and kenter shackle or less may be omitted.

(4) When the test for anchor shackle has been passed, the approval test for manufacturing process of the connecting shackle of the same diameter thereof or less may be omitted.

(5) When the test either for connecting shackle of anchor shackle has been passed, the approval test for manufacturing process of the enlarged link and end link of the same diameter thereof or less may be omitted.

(6) The diameter of the chain accessories shown in items (1) through (5) above corresponding to that of the common link to which they are fitted.

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Table 2.3-1 Approval Test Items and Acceptance Criteria for Accessories

Note:

(1) The test chain accessories used for approval test are to, in principle, be two or three, in number, of the larges diameter under application.


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(2) Temperatures of impact test are to be in accordance with Table 2.3-2. (3) In the case of the approval test required in connection with the change in the manufacturing as shown in 3.5, the

Society may reduce the requirements in the diameter and number of test chain accessories with respect to the test items.

(4) When any steel materials, manufacturing process or heat treatment not specified in the Rules are intended to be used, the Society may request other testing procedure or submission of reference data in addition to those specified in the Rules.

Table 2.3-2 Temperatures of Impact Test

Kind of chain

Accessories

Number of

test specimen

Temperature Minimum absorbed average energy (J)

Grade 2 chain

Accessories

1 set 0 To be with reference.

Grade 3 chain

Accessories

2 sets 0 and

-20

At 0 to be of 60 J.

At other temperature to be with reference.

Grade R3

offshore chain

accessories

3 sets At 0 to be of 60 J.

At -20 to be of 40 J.

At -40 to be with reference.

Grade R3S

offshore chain

accessories

3 sets 0,-20

and -40

At 0 to be of 65 J.

At -20 to be of 45 J.

At -40 to be with reference.

Grade R4

offshore chain

accessories

3 sets At -20 to be of 50 J.

At other temperatures to be with reference.

3.5 Handling of Change in Manufacturing Process

3.5.1 Handling of Change in Manufacturing Process Where major changes largely affecting the manufacturing process already approved have been made, the provisions in 2.7.1 are to apply.

3.6 Approval

3.6.1 Notification of Approval For the notification of approval, the provisions in 2.6 are to apply.

3.7 Others

3.7.1 Using of Outside Manufacturing Facilities and Revocations of Approval The requirements when lease of manufacturing facilities is intended, or when revocation of approval is made, the provisions in 2.6 are to apply.

Part 2 Chapter 4

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Chapter 4 APPROVAL OF RAW TEXTILES FOR SYNTHETIC FIBRE ROPES

4.1 General

4.1.1 Scope The approval of the manufacturing process of raw textiles for synthetic fibre ropes specified in the provisions of 5.1.3-1, Part L of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”) is to be carried out in accordance with the provisions of this chapter.


4.2.1 Application Procedures The manufacturer of raw textiles who intends to obtain approval of the manufacturing process of raw textiles is to submit his application for approval with the following reference data in (1) to (4) below to the Society.

In case where reference data compatible with those to be newly submitted were previously submitted to the Society, submission of such reference data may be omitted by giving notification to the Society to that extent. (1) Outline of raw textiles manufacturing factory (2) Raw textiles manufacturing process (3) Characteristics of raw textiles (heat-resistance, oil-resistance and others as considered necessary by the Society) (4) Testing facilities and product quality control organization for raw textiles


The Society is to carry out confirmation survey to confirm the manufacturer of raw textiles is capable of manufacturing products of stable quality (manufacturing facilities, techniques, product quality control and inspection organizations) on the basis of the information contained in the above reference data.

4.4 Approval Test

4.4.1 Testing Items 1 Test Items are to be as follows : (1) Linear strength and elongation tests (2) Chemical resistance test 2 The tests specified in -1 above are to be carried out in the presence of the surveyor of the Society.

Provided, however, approval test is carried out in the organization authorized by the Society (officially recognized establishment), the witness by the Surveyor of the Society may be omitted.

4.4.2 Test Procedures The procedures of the tests specified in 4.4.1-1 above are to be in accordance with the following requirements: (1) Linear strength and elongation tests

The number of test specimens used in the test is to be 10, and average value of the measured values of linear strength and elongation on these test specimens are to be obtained. The average value of linear strength and elongation values thus obtained are to satisfy those given in Table 2.4-1.

(2) Chemical resistance test The chemical resistance tests are to comprise alkali-resistance test and acid-resistance test. In alkali-resistance test, the test specimen is to be soaked in 10% caustic soda solution at a temperature 20± 2 for a period of 24 hours, whereas in acid-resistance test, the test specimen is to be soaked in 10% acid solution at a temperature 20± 2 for a period of 24 hours, and then rinsed with water, and the linear strength is to be measured by the same method as in (1) above. The number of test specimens are to be 10 for each chemical solution. The linear


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strength is to be converted into the value of residual strength ratio of chemical resistance by the following equation. These average values are to satisfy the values given in Table 2.4-1.

4.4.3 Submission of Test Reports The manufacturer is to prepare test reports after completion of the tests, obtain the surveyor’s signature thereon, and is to submit them, in triplicate, to the Society.

Table 2.4-1 Standard Tensile Strength Values for Raw Textiles

Kind of raw textiles Mechanical properties Residual chemical resistance strength ratio (%)

Linear strength (g/D)

Linear elongation(%)

10% sulphuric acid 10% caustic soda

Vinylon for Grade 1 Span, mono-filament

4.0 or more 9~18 90 or more 90 or more

for Grade 2 Multi- filament 6.0 or more 9~18 90 or more 90 or more Polyethylene for Grade 1 Mono- filament 6.5 or more 5~25 90 or more 90 or more

for Grade 2 Mono- filament 8.5 or more 5~15 95 or more 95 or more

Polyester Multi- filament 5.5 or more 10~20 90 or more 90 or more

for Grade 1 Span 4.5 or more 10~20 90 or more 90 or more Mono- filament 6.0 or more 10~20 90 or more 90 or more

Poly- Multi- filament 6.5 or more 15~25 90 or more 90 or more

propyrene Special mono-filament


for Grade 2 Special multi-filament


Split 4.0 or more 5~15 90 or more 90 or more

Nylon Multi- filament 6.5 or more 15~30 80 or more 80 or more

Note: g/D signifies gram/denier

4.5 Approval

4.5.1 Notification of Approval The Society, when it considers that the results of confirmation and approval tests of manufacturer process are appropriate, is to approve the manufacturing process of raw textiles applied for, give notice to the manufacturer and at the same time, the Society is to notify.

4.5.2 Revocation of Approval Approval may be revoked in either case of the following circumstances. (1) When question arises on product quality. (2) When question arises on the product quality control activities. (3) When the approval has become no longer applicable due to amendment of rules and others. (4) When manufacture of the product has been terminated. (5) When revocation of the approval is applied by the manufacturer.

Part 2 Chapter 5

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Chapter 5 APPROVAL OF MANUFACTURING PROCESS OF SYNTHETIC FIBRE ROPES

5.1 General

5.1.1 Scope This chapter applies to the approval of manufacturing process of synthetic fibrel ropes specif1ied in 5.1.3-2, Part L of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”).


5.2.1 Application Procedures Manufacturer who intends to obtain approval of manufacturing process of synthetic fibre ropes is to submit his application accompanied by reference data on the following items, each in triplicate, to the Society: (1) Outline of manufacturing factory (2) Outline of manufacturing process (including the manufacturing process of end of fibre ropes such as eye splice) (3) Testing facilities and product quality control organizations (4) Name of manufacturer of raw textiles and brand name of them.


The Society is to carry out confirmation survey of manufacturing and quality control procedure, on the basis of the above reference data submitted, to confirm the manufacturer of ropes is capable of manufacturing the products always in stable quality. For the rope manufacturing factory who had obtained approval of the Society on rope products of other brand, the confirmation survey may be omitted.

5.4 Approval Test

5.4.1 Test Items 1 Items of approval test are to be as follows : (1) Tensile test (the effects of change in

temperature of water in a range from 0 to 45 are also to be examined) in both wet and dry conditions (2) Abrasive resistance tensile test (3) Weather resistance tensile test (or tensile test after exposing the test specimen to weather for a period of half a

year) (4) Other tests as considered necessary by the Society 2 The tests specified in -1 above are to be carried out in the presence of the surveyor of the Society. However, when approval test is carried out in the organization authorized by the Society (officially recognized establishment), the witness by the Surveyor of the Society may be omitted. 3 The test procedures for -1 above are to be in accordance with the following requirements: (1) Tensile tests in wet and dry conditions

Tensile tests on three each test specimens are to, in principle, be carried out for each of the test conditions give in Table 2.5-1, and breaking strength and elongation are to be measured. Except on cases with vinylon and nylon in wet condition, respective breaking loads are to satisfy the requirements specified in Table L5.1, Part L of the Rules. The breaking loads of vinylon and nylon in wet conditions are to be 80% or more and 90% or more respectively of the values given in the Table L5.1, Part L of the Rules. Values with respect to elongation are to be for reference only. The gauge length of the test specimen to be 30 times or more the rope diameter, however it needs not to exceed 1 meter.


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Table 2.5-1 Test Conditions Diameter Kind of rope

of test rope Vinylon rope polyester rope nylon rope

Polyethylene rope polypropylene rope

12-24mm Wet condition(1) Wet condition(3)

Dry condition(2) Dry condition(2) 40-60mm Wet condition(1) Wet condition(3)

Dry condition(2) Dry condition(2)

Notes: (1) The test specimen is to be soaked in water at normal temperature for a period of 30 minutes or more, then taken out

and subjected to tensile test at room temperature. (2) The test specimen in dry condition is to be subjected to tensile test at room temperature. (3) The test specimen is to be soaked in warm water at temperature of 35±2 for a period of 30 minutes or more, then

taken out and immediately subjected to tensile test at room temperature.

(2) Abration resistance tensile test A total of six test specimens are to be taken from ropes with diameter from 12 to 24 mm. Three of them are to be set in the abrasion resistance testing machine with the following particulars, and are to be subjected to repeated strokes for 500 times.

Stroke: 200-300 mm Abrasion speed: 50 strokes/mm Abrasion surface: Grinder with particle size No.120 Tensile load: 98N

Those three tested specimens together with other three non-tested specimens are to be placed in a thermostatic oven kept at a temperature of 20 and a humidity of 65%, and left there for one hour. They are then to be taken out, and be subjected to tensile tests for measuring the tensile strength and elongation, whereby the strength values of the rope before and after abrasion are to be compared. The ratio of the residual abrasion strength to the strength without abrasion (the residual abration strength ratio) is to satisfy the values given in Table 2.5-2. For other test conditions than those shown above, they are to considered appropriate by the Society.

(3) Weather resistance test A total of six test specimens are to be taken from ropes with diameter from 12 to 24 mm. Three of these test specimens are to be placed in the weather resistance test machine controlled to the following conditions where they are to be left for 200 hours or more.

Weathering light: Sunshine carbon arc light or ultraviolet carbon arc light Temperature of black panel: 63±1 Period of water spray: 18 min/2hours

The six test specimens including those three non-tested specimens are then to be placed in a thermostatic oven kept at a temperature of 20 and a humidity of 65%, and left there for one hour. These test specimens are to be taken out, tensile strength and elongation are to be measured, and the strength after the weathering resistance test and that of the test specimens not subjected to such weathering resistance test are to be compared. The ratio of the former to the latter (the residual weathering strength ratio) is to satisfy the values given in Table 2.5-2.

5.4.2 Submission of Test Report The manufacturer is to prepare test report after completion of the tests, receive signature of the surveyor who witnessed the tests, and is to submit them, in triplicate, to the Society.

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5.5 Approval

5.5.1 Notification of Approval The Society, when it considers the results of confirmation and approval tests of manufacturing process appropriate, is to give approval of the manufacturing process of the ropes to the manufacturer, send a notification of approval.

5.5.2 Revocation of Approval The approval may be revoked in either of the following circumstances: (1) When question arises on product quality. (2) When question arises on the product quality control activities. (3) When the approval has become no longer applicable due to amendment of the rules. (4) When the manufacture has been terminated. (5) When revocation of the approval is applied by the manufacturer.

5.6 Periodical Inspection

1 General The manufacturer is to be subjected to periodical inspection for the facilities and process of manufacturing for approved synthetic fibre ropes in a period not exceeding four years. 2 Application for Inspection The manufacturer is to submit to the Society a single copy of application form (see Form 2-4) and three copies of the list of the products of which approval are intended to be continued or revoked. In this case, this list is to be filled in with product name, manufacturer and kind of filaments, whether the inspection has been carried out by the Society or not during the last four years, production output in the last one year, whether the approval is to be continued or not, etc. The approval is to be revoked in case filaments of the rope which have not been manufactured any longer. 3 Details of Inspection (1) The confirmation survey is to be carried out in accordance with the provisions in 5.3. (2) In the inspections, breaking test specified in 5.1.7, Part L of the Rules for the Survey and Construction of

Steel Ships is to be carried out according to the category specified in Table 2.5-3. In each category, one specimen is to be taken from every three coils of ropes which are larger than 40mm or the largest size manufactured in diameter. Each specimen is to satisfy the provisions in 5.1.7(4), Part L of the Rules for the Survey and Construction of Steel Ships. However, for the works where rope inspections have been carried out by the Society during the last four years for a division, periodical inspection may be dispensed with.

Table 2.5-2 Residual Strength Ratio of Synthetic Fibre Ropes

Kind of rope Residual abrasion strength ratio (%)

Residual weathering strength ratio (%)

Vinylon rope 50 or more 90 or more

Polyethylene rope

55 or more 80 or more

Polyester rope 55 or more 90 or more

Polypropyene rope

55 or more 80 or more

Nylon rope 55 or more 80 or more

Table 2.5-3 Division of Synthetic Ropes Vinylon Ropes Grade 1 Grade 2

Polyethylene Ropes Grade 1

Grade 2

Polyester Ropes Polypropylene Ropes Grade 1

Grade 2 Nylon Ropes


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Form 2-4

Part 2 Chapter 6

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Chapter 6 EMERGENCY TOWING ARRANGEMENTS

6.1 General

6.1.1 Scope 1 This Chapter applies to the approval of prototype of emergency towing arrangements (Hereinafter referred to as “ETA” in this Chapter.) and examinations, tests and inspection of products of ETA based upon the requirements specified in C27.3.2-1, Part C of the Guidance for the Survey and Construction of Steel Ships. Where tests for approval of prototype of ETA mean the examinations and tests in order to confirm that the prototype of ETA made of components listed in Table C27.3.2-2, Part C of the Guidance for the Survey and Construction of Steel Ships complies with the requirements specified in C27.3, Part C of the Guidance for the Survey and Construction of Steel Ships, and production tests of ETA mean the examinations and tests to be carried out against the products of each component of ETA which has obtained the approval of the prototype. 2 Test for approval of prototype of ETA and production tests of each component of ETA are to be carried out separately.


1 Manufacturer who intends to obtain approval of prototype of ETA is to submit application (See Form 2-6) accompanied by three sets of the following data. (1) Outline of manufacturing plant (brochure showing the outline of manufacturing plant.) (2) Outline of manufacturing process (manufacturing process for each component of ETA respectively.) (3) Description of quality control systems and quality control standards (4) Specification of ETA (5) Description of type and specification of each component of ETA (6) General arrangement of ETA and construction profile of each component in detail (indicate materials used

clearly) (7) Operation Manuals for ETA (8) Description of name and address of all factories, where each component of ETA is manufactured by different

factories. (9) Kinds, mechanical properties and chemical composition of materials of each component (10) Description of heat treatment process (including kind of method, temperature, time of heat treatment and kind of

cooling method and so on) and their control standards, if the materials used require the heat treatment. (11) Inspection and testing facility including non-destructive testing method and list of certified personnel in charge

of non-destructive testing. (12) Copy of Certification issued by other Classification Society or other organizations considered appropriately by

the Society, if the manufacture has already obtained approval of manufacturing process. (13) Copy of Certification issued by the Society or other recognized organizations based on the Rules for Approval

of Manufacturers or ISO 9000 series, if the manufacture has already obtained approval of its quality system. (14) Approval test plan of ETA including testing method 2 The submission of the data specified in -1 may be omitted in case where manufacture previously submitted these data to the Society. In this case, manufacture is to submit an application form fitted with the document to that effect.

6.3 Confirmation Survey of Manufacturing Factory

6.3.1 Confirmation Survey of Manufacturing Factory The Society may carry out confirmation survey on facilities, manufacturing techniques, product quality control and inspection by manufacture of the manufacturing factory based on the data specified in 6.2 in order to verify the factory’s ability of manufacturing ETA product of stable quality.


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6.4 Prototype Test

6.4.1 Items of Prototype Test The following prototype tests are to be carried out under the presence of the Surveyor. (1) Strength test (2) Deployment test (3) Other tests as considered necessary by the Society

6.4.2 Strength Test 1 Towing pennant or chafing gear is to be tensioned for at least 1 minute in the lateral direction of 90 degrees and in the downwards direction of 30 degrees at the load specified in the following (1) or (2) corresponding to the type of ETA, after towing pennant, chafing gear, fairlead and strongpoint among the components of ETA have been arranged according to the general arrangement of ETA. Each component of ETA is to withstand the above test without breaking or collapse. (1) For 1,000 kN type ETA : 2,000 kN (2) For 2,000 kN type ETA : 4,000 kN 2 For towing pennant, chafing chain, fairlead and strongpoint used as the strength test specified in -1 above, it is to be verified that each component is in compliance with the requirements specified in Part K or Part L of the Rules for the Survey and Construction of Steel Ships or with an other standard which is left to the discretion of the Society. For fairlead and strongpoint, ultrasonic test is to be carried out overall of materials, as a rule. If it is difficult to carry out an ultrasonic test due to the feature of components of ETA, a suitable non-destructive test such as magnetic test may be accepted. (1) For towing pennant : Breaking test (2) For chafing chain : Tests required in 3.1, Part L of the Rules for the Survey and Construction of Steel Ships.

Where these chains are manufactured by the manufacturer whose manufacturer whose manufacturing process has been approved by the Society or other Classification Societies considered appropriate by the Society, the presence of Surveyor to these tests may be dispensed with subject to submission of the tests records. Test for pear-shaped link used for the end of chafing chain may also be dispensed with where its manufacturing process has been submitted to and approved by the Society.

(3) For fairlead and strongpoint : Materials tests in accordance with the recognized standards (ex. JIS or DIN, etc.) or Rules (ex. Part K of the Rules for the Survey and Construction of Steel Ships, etc.) as designated by the manufacturer. However, analysis of chemical composition may be dispensed with in the case where chemical composition of materials can be confirmed by the certificate of the mill maker. Ultrasonic test is to be carried out overall of materials, as a rule. If it is difficult to carry out a ultrasonic test due to the feature of components of ETA, a suitable non-destructive test such as magnetic test may be accepted.

3 For components of ETA other than those prescribed in -2, the Society may require to carry out the test and examination prior to the strength test specified in -1, where considered necessary.

6.4.3 Deployment Test Deployment test mentioned in the following (1) and (2) is to be carried out at night after ETA has been installed on board. In this testing condition, a ship’s power is to be supplied only by an emergency power. (1) For the pre-rigged ETA, the following items specified in (a) and (b) are to be confirmed after the ETA has been

deployed in accordance with the operation manual. (a) To be capable of being deployed in harbour conditions within 15 minutes. (b) Pick-up gear to be capable of being manual operative by one person

(2) For the non-pre-rigged ETA, capability of being deployed in harbour conditions within 1 hour is to be confirmed by deploying the ETA in accordance with the operation manual. In this testing condition, operators on board are to be of maximum 10 persons

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6.5 Submission of Test Records

6.5.1 General The manufacturer is to make the test records after approval tests described in 6.4 have been completed and is to submit the tests record in deplicate, endorsed by the attended surveyor to the Society.


6.6.1 Notification of approval The Society upon finding that the results of confirmation survey of manufacturing factory and the record of prototype tests are all satisfactory, it to approve the prototype of ETA, and send a notice of approval describing the following contents to the applicant and inform the branch office within jurisdiction of address of the applicant to that effect. (1) Trade name of ETA, type and name of applicant (2) Type of major components of ETA and name of manufacturer respectively (3) Testing load

6.7 Revocation of Approval

6.7.1 Revocation of Approval The Society may revoke approval of prototype in either case of the following circumstances. (1) When question arises on product quality. (2) When question arises on the product quality control activities. (3) When manufacture of the product has been terminated. (4) When revocation of the approval is applied by the manufacturer.

6.8 Dealing with Changes in Manufacturing Process, etc.

6.8.1 Dealing with changes in manufacturing process, etc. Where there are changes in manufacturing process, changes or additions in the name of manufacturer who manufactures each component of ETA, changes in quality control system, and so on, manufacturers are to give a notice to the Society. In this case, the Society may require additional tests to the manufacture, where considered necessary.

6.9 Examinations for Products

6.9.1 Examination for products 1 For towing pennant, chafing chain, fairlead and strongpoint, it is to be verified that each component has been manufactured in the same specification as those used for approval test of prototype of ETA and is in compliance with the requirements in Part K or Part L of the Rules for the Survey and Construction of Steel Ships or with an other standard which is left to the discretion of the Society. Notwithstanding the requirements specified in Part L of the Rules for the Survey and Construction of Steel Ships, however, it may be acceptable to verify that the breaking load of towing pennant, which is calculated based upon the result of tensile tests of each individual wire strand in accordance with the calculation method specified in Annex 2 of JIS G 3525, satisfies the relevant standards in lieu of carrying out a breaking test for towing pennant. 2 Among the components of ETA other than specified in -1 above, tests and examination may be required at the discretion of the Society to be carried out under the presence of the Surveyor. 3 For the components other than specified in -1 and -2 above, suitable tests and/or examination are to be carried out under the manufacturer’s responsibility.


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Form 2-6

Part 2 Chapter 7

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Chapter 7 LIFE-SAVING APPLIANCES

7.1 General

7.1.1 Application 1 This Chapter applies to tests and inspections for type approval/approval of appliances or equipment under Chapter 3 of the Rules for Safety Equipment with respect to the following: (1) Lifeboats; (2) Rescue boats; (3) Inflatable liferafts; (4) Launching appliances for lifeboats, rescue boats and liferafts; (5) Engines for lifeboats and rescue boats (including reduction and reversing gears). 2 Components constituting any part of the appliances or equipment referred to in -1 above may be type approved/approved in accordance with this Chapter whenever applications are submitted.

7.2 Type Approval

7.2.1 Procedures for Application 1 An applicant for type approval is to submit an “Application for Type Approval (Initial)” (Form 2-6) and the following drawings and documents for examination, each in triplicate: (1) Drawings and documents for type approval; (2) Prototype test procedures for type approval; (3) Outline of the manufacturer’s production site including:

(a) their location, history, capital stock, organizational structure, number of employees, main products and standard production capability thereof;

(4) Manufacturing facilities including: (a) lists of main production facilities and test/inspection facilities; (b) outline of each shop site and storage facilities for materials and parts;

3 lists of subcontracted manufacturers and parts. (5) Documents related to quality control including:

(a) organizational structure related to quality control; (b) document control; (c) in-house test and inspection procedures; (d) management of inspection, measurement and test facilities; (e) management of nonconformities; (f) management of quality records.

2 Irrespective of the above -1, the applicant may submit an “Application for Omission of Drawings and Documents” (Form 2-8) only, in triplicate, instead of submitting the relevant drawings and documents, if they are identical to drawings and documents already submitted to the Society in relation to appliances or equipment previously type approved by the Society.

7.2.2 Examination of Manufacturer’s Production Site The Society is to review the documents submitted in accordance with 7.2.1-1(5) above and, where deemed appropriate, conduct an examination of the actual production site of the manufacturer to ensure that the quality control system is implemented in accordance with the documents submitted.

7.2.3 Prototype Tests for Type Approval 1 Once the examination of the production site of the manufacturer and of the review of the prototype test procedures for type approval submitted in accordance with 7.2.1-1(2) above has been completed with satisfactory


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results, the prototype test procedures are to be approved and returned to the applicant. 2 Tests and inspections as part of the prototype test are to be carried out, in principle, at the production site of the manufacturer of the appliance or equipment. In cases where the appliance or equipment has been type approved by another organization which the Society recognizes as appropriate in accordance with the requirements of the 1983 Amendments to the International Convention for the Safety of Life at Sea, 1974 and subsequent amendments, and of IMO Assembly Resolution A. 689(17) “Recommendation on Testing of Life-saving Appliances”, and further where the documents including the relevant test records are submitted and reviewed with saitsfactory results, the Society may exempt such appliances or equipment from undergoing prototype tests in whole or in part. 3 The timing of attendance by the Surveyor is to be as follows: (1) when fabrication of main parts for which attendance is deemed necessary is carried out; and (2) when tests and inspections as the prototype test are carried out. 4 After completion of the prototype test, the applicant is to compile the test results and submit the test records endorsed by the attending Surveyor in triplicate to the Society.

7.2.4 Certificate of Type Approval 1 Once the examination of the production site of the manufacturer and the review of the results of the prototype test have been completed satisfactorily, the Society is to type approve for the appliance or equipment manufactured by the production site, and is to issue a Certificate of Type Approval to the applicant. The Certificate issued and drawings approved are to indicate the type approval number, date/month/year of the type approval and conditions for the type approval, if any, etc. The Certificate and the drawings are then to be forwarded to the applicant. 2 The term of validity of the type approval of appliances and equipment will be five years from the date of approval.

7.2.5 Renewal of Validity of Certificate of Type Approval 1 When a firm that has been issued with a Certificate of Type Approval for a given appliance or item of equipment wishes to renew the Certificate, the firm is to submit an “Application for Approval (Renewal)” (Form 2-6) with a list of the appliances or equipment manufactured in the past in triplicate to the Society within the validity of the Certificate. 2 The Society is to conduct an examination of the implementation of the quality control system in place at the production site of the manufacturer in accordance with 7.2.2 above. When the Society considers it appropriate, however, the scope of the examination may be reduced. 3 In cases where the results of the examination carried out in accordance with -2 above is considered appropriate, the Certificate is to be renewed. The expiration date of the renewal is to be the fifth anniversary after the date of renewal.

7.2.6 Modification in Approval Conditions When modifications are planned by a firm that has obtained type approval for a given appliance or item of equipment with regard to approval contents with respect to the particulars, materials used, structures, scantlings and manufacturing processes of the main parts, or the quality control system used, the firm is to submit an “Application for Approval (Modification)” (Form 2-6) with an explanatory note describing the modifications in contents and related drawings/documents in triplicate to the Society. The Society is to examine the proposed modifications, and may require tests and/or inspections, as deemed necessary.

7.2.7 Revocation of Type Approval In the following cases, the Society may revoke approval and notify the firm of such revocation of type approval: (1) where there are doubts as to the quality of the appliances or equipment which have been type approved or

regarding the implementation of the quality control system of the production site of the manufacturer, and where an investigation into the situation results in a determination being made by the Society that the continuation of the approval is not considered appropriate;

(2) where the type approved appliances or equipment are no longer permitted to be used under subsequent amendments to International Conventions; or

(3) where the Society receives an application for revocation of type approval.

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7.3 Production Tests

7.3.1 General A production test is to be conducted for each of the appliances or equipment type approved by the Society to ensure that each item is manufactured to the same standard as the approved prototype.

7.3.2 Procedures for Application An applicant applying for a production test is to submit an “Application for Tests (Production Tests)” (Form 2-7) to the nearest branch or office of the Society.

7.3.3 Tests and Inspections 1 A production test is to consist of an examination of implementation of the quality control system in place at the production site of the manufacturer for the type approved appliance or equipment and of witnessing tests and inspections required as part of the production test. 2 During the examination of the of implementation of the quality control system, the applicant is to show the Surveyor records of various measurements and of in-house tests and inspections specified as part of the quality control system of the production site of the manufacturer. Examination of the quality control system of the production site of the manufacturer in accordance with 7.2.2 above may be required in cases where it is deemed necessary by the Surveyor to do so as, for example, when a production test has not been conducted for a long time and when such examination has not been conducted accordingly. 3 Tests and inspections as part of the production test carried out for appliances or equipment are in principle to be conducted at the production site of the manufacturer. 4 Appliances or equipment which have been successfully subjected to production tests with satisfactory results are to be marked or stamped for identification, and are also to be marked with the following at some appropriate location on each piece: (1) type approval number of the Society; (2) serial number of the manufacturer; and (3) date, month and year of the manufacture. 5 The Society is to issue a Certificate for each appliance or item of equipment subjected to production tests with satisfactory results.

7.3.4 Modifications to Tests, Inspections and Their Methods With due consideration to appliance and equipment design, methods of manufacture, production volume and implementation of the quality control system, the Society may accept equivalency to tests and/or inspections of the appliances or equipment as specified in 7.5 to 7.9.

7.3.5 Omission of Witness at Tests and/or Inspections 1 With due consideration to appliances and equipment design, methods of manufacture, production volume and implementation of the quality control system, the Society may increase or decrease the number and type of test items and/or inspection items which need to be carried out in the presence of the Surveyor of the Society. 2 In cases where the production side of a manufacturer has been approved under the Rules for Approval of Manufacturer for appliances or equipment for which type approval is being sought, the Society may accept tests and/or inspections on a sampling basis which are suitable for the kinds and number of appliances or equipment being considered in place of requiring the Surveyor either at tests and/or inspections as specified separately or at equivalent tests and/or inspections accepted under 7.3.4 above. The production site, however, are to conduct all such tests and/or inspections specified separately or all equivalent tests and/or inspections accepted under 7.3.4 above through the whole manufacturing process. The appliances or equipment manufactured according to the foregoing are to be marked with the type approval number, date/month/year of manufacture, serial number of the manufacturer, etc. under the approval of the Society. 3 Where the procedure specified in -2 above is accepted, the person responsible for quality control at the production site of the manufacturer is to submit a Request for the Issue of a Certificate and a report containing the serial number of the production site of the manufacturer, date/month/year of the manufacture, main particulars, results of in-house tests and inspections for the appliances or equipment to a branch office of the Society for action.


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The branch office is to issue the Certificate to the applicant after having reviewed the report and finding it to be satisfactory.

7.4 Approval for Appliances or Equipment Not Type Approved by the Society

7.4.1 Application The Society may carry out tests and/or inspections for appliances or equipment not type approved by the Society in line with those required for type approval, approve them and issue a Certificate of Approval after satisfactory results have been confirmed with regard to the tests and/or inspections if the Society considers it not to be practicable for them to acquire type approval and to have subsequent production tests and if the Society also considers it to be inevitable to do so.

7.4.2 Markings The method of marking appliances or equipment subjected to such tests and/or inspections with satisfactory results is to be in accordance with the provisions specified in 7.3.3-4 above with the exception of the marking of type approval number.

7.5 Lifeboats

7.5.1 Lifeboat Engines, Equipment, etc. 1 Lifeboat engines (including reduction and reversing gears) are to be in compliance with 7.9 “Engines for Lifeboats and Rescue Boats”. 2 Among the lifeboat fittings and equipment, the following are to be of a type approved either by the flag government of the ship where they are carried, by contracting governments to the SOLAS Convention in force or by the organizations recognized by these governments: (1) Portable fire-extinguishing equipment; (2) High-pressure gas cylinders; (3) External lamps; (4) Internal lamps (in case either dry cell or sea water cell is used); (5) Lifeboat equipment:

(a) Thermal protective aids; (b) Food rations; (c) De-salting apparatus; (d) First-aid outfits; (e) Rocket parachute flares; (f) Buoyant smoke signals; (g) Hand flares; (h) Searchlights;

(6) Retro-reflective materials.

7.5.2 Type Approval 1 Drawings and documents data to be submitted Drawings and documents to be submitted are specified in 7.2.1-1(2) to (5) and the following, each in triplicate: (1) Specifications; (2) General arrangement; (3) Hull construction; (4) Inherent buoyant material arrangement; (5) Arrangement of lifeboat fittings including fenders and lifelines; (6) Steering gear and rudder construction; (7) General arrangement of propelling machinery; (8) Propeller shaft arrangement; (9) Door arrangement and its details; (10) Seating arrangement;

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(11) Release mechanism; (12) Fitting of retro-reflective materials; (13) Wiring diagram; (14) List of materials used (including fire-retardancy data); (15) List of lifeboat equipment; (16) Self-contained air support system (for lifeboats with self-contained air support system and for fire-protected

lifeboats); (17) Water spray piping system (for fire-protected lifeboats); (18) Lines of hull; (19) Laminating procedures and details of joints (for FRP lifeboats); (20) Structural strength calculations and data; (21) Buoyancy calculations for inherent buoyant materials; (22) Stability calculations and data; (23) Maintenance and inspection manuals; (24) Other drawings and documents which the Society deems necessary. 2 Prototype Test A prototype test is to consist of the following tests and inspections. The procedures for tests on material, strength and performance are to be in accordance with Chapter 1 “Procedures for Prototype Tests for Type Approval of Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”: (1) Material tests:

(a) Material test for boat hulls and rigid covers; (b) Material test for inherent buoyant materials;

(2) External and construction inspections: (a) External and construction inspection; (b) Dimension measurement; (c) Mass measurement; (d) Freeboard measurement; (e) Lifeboat equipment inspection; (f) Marking inspection;

(3) Strength and performance tests: (a) Launch test; (b) Lifeboat overload test; (c) Davit-launched lifeboat impact and drop test; (d) Free-fall lifeboat free-fall test; (e) Lifeboat seating strength test; (f) Lifeboat seating space test;

i) Boarding and seating test ii) Non-skid finish inspection

(g) Lifeboat freeboard and stability tests; i) Flooded stability test ii) Freeboard test

(h) Release mechanism test; (i) Lifeboat operation test;

i) Operation of lifeboat engine and fuel consumption test ii) Compass

(j) Lifeboat towing and painter release test; (k) Lifeboat light test; (l) Other performance tests;

i) Retrieval test ii) Emergency steering test iii) Watertightness test for battery casings iv) Charging test


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v) Rowing test for davit-launched lifeboats vi) Effectiveness test for bailing means

(m) Additional tests for partially enclosed lifeboats; i) Canopy erection test

(n) Additional tests for self-righting partially enclosed lifeboats; i) Canopy erection test ii) Self-righting test iii) Flooded capsizing test iv) Strength and holding tests for safety belts

(o) Additional tests for totally enclosed lifeboats; i) Tests as specified in (n) above with the exception of canopy erection test ii) Atmospheric pressure holding test iii) Watertightness test for hatches

(q) Additional tests for lifeboats with a self-contained air support system; i) Tests as specified in (o) above ii) Air supply test

(r) Additional tests for fire-protected lifeboats; i) Tests as specified in (q) above ii) Fire test iii) Water spray test

7.5.3 Production Test 1 Inspection A production test is to consist of the examination of the implementation of the quality control system of the production site of the manufacturer and of the respective records, and of the following tests and inspections. The procedures for strength and performance tests are to be in accordance with Chapter 2 “Procedures for Production Tests of Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”: (1) External and construction inspections:

(a) External and construction inspection; (b) Dimension measurement; (c) Mass measurement; (d) Freeboard measurement (in fully loaded condition); (e) Lifeboat equipment inspection; (f) Marking inspection;

(2) Strength and performance tests: (a) Performance test of release mechanisms of davit launched lifeboats; (b) Operation test.

2 Inspection for Markings Lifeboats which have been subjected to the production test with satisfactory result are to be marked with the markings as specified in 7.3.3-4 in clear permanent characters.

7.6 Rescue Boats

7.6.1 Application The provisions as specified in 7.6 are to apply to davit-launched rescue boats.

7.6.2 Rescue Boat Engines and Equipment 1 The rescue boat engines are to be in accordance with 7.9 “Engines for Lifeboats and Rescue Boats”. 2 Among the rescue boat fittings and equipment, the following are to be of a type approved either by the flag government of the ship where they are carried, by contracting governments to the SOLAS Convention in force or by organizations recognized by these governments: (1) Rescue boat equipment:

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(a) Thermal protective aids; (b) First aid outfits; (c) Search lights;

(2) Retro-reflective materials.

7.6.3 Type Approval 1 Drawings and documents to be submitted Drawings and documents to be submitted are specified in 7.2.1-1(2) to (5) and 7.5.2-1(1) to (15) and (18) to (24) and the following, each in triplicate: (1) Air chamber structure and arrangement of inflated and combined rescue boats (2) Air chamber/transom joining procedures of inflated rescue boats (3) Hull and air chamber/transom joining procedures of combined rescue boats 2 Prototype Test A prototype test is to consist of the following tests and inspections. The procedures for tests on material, strength and performance are to be in accordance with Chapter 1 “Procedures for Prototype Tests for Type Approval of Rescue Boats” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”: (1) Material test:

(a) Material test for boat hulls; (b) Material test for rigid covers; (c) Material test for buoyant materials;

(2) Inflated rescue boats: (a) Material test for boat hull;

(3) Combined rescue boats: (a) Material test for boat hull; (b) Material test for buoyant materials;

(4) External and construction inspections: (a) External and construction inspection; (b) Dimension measurement; (c) Mass measurement; (d) Freeboard measurement; (e) Rescue boat equipment inspection; (f) Marking inspection;

(5) Strength and performance tests: (a) Rigid rescue boats;

i) Launch test ii) Overload test iii) Impact and drop tests iv) Seating strength test v) Seating space test vi) Non-skid finish inspection vii) Freeboard and stability tests

1) Flooded rescue boat stability test 2) Freeboard measurement

viii) Release mechanism test ix) Operation tests x) Towing and painter release test xi) Other performance tests

1) Retrieval test 2) Emergency steering test 3) Watertightness test of battery casings 4) Charging test


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5) Effectiveness test for bailing means (b) Inflated rescue boats;

i) Launch test ii) Overload test iii) Impact test iv) Drop test v) Seating strength test vi) Seating space test vii) Non-skid finish inspection viii) Loading test (Freeboard measurement) ix) Stability test x) Damage test xi) Swamp test xii) Release mechanism test xiii) Operation test xiv) Manoeuvrability and towing xv) Towing and painter release test xvi) Righting test xvii) Simulated heavy weather test xviii) Mooring out test xix) Other performance tests

1) Bringing of stretchers into the rescue boat 2) Emergency steering test 3) Watertightness test for battery casings 4) Charging test 5) Effectiveness test for bailing means

xx) Detailed inspection (c) Combined rescue boats;

i) Launch test ii) Overload test iii) Impact test iv) Drop test v) Seating strength test vi) Seating space test vii) Non-skid finish inspection viii) Loading test (Freeboard measurement) ix) Stability test x) Damage test xi) Swamp test xii) Release mechanism test xiii) Operation test xiv) Manoeuvrability and towing tests xv) Towing and painter release test xvi) Righting test xvii) Simulated heavy weather test xviii) Mooring out test xix) Other performance tests

1) Test for bringing of stretchers into the rescue boat 2) Emergency steering test 3) Watertightness test for battery casings 4) Charging test 5) Effectiveness test for bailing means

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xx) Detailed inspection

7.6.4 Production Test 1 Inspection A production test is to consist of the examination of the implementation of the quality control system of the production site of the manufacturer and of the respective records, and of the following tests and inspections. The procedures for tests on strength and performance are to be in accordance with Chapter 2 “Procedures for Production Tests of Rescue Boats” of Annex 2 “Procedures for Prototype Tests for Type approval and Production Tests of Rescue Boats”: (1) External and construction inspections:

(a) External and construction inspection; (b) Dimension measurement; (c) Mass measurement; (d) Freeboard measurement (in fully loaded condition); (e) Rescue boat equipment inspection; (f) Marking inspection;

(2) Strength and performance tests: (a) Release mechanism test; (b) Overload, pressure and tightness tests for inflated and combined rescue boats; (c) Operation test.

2 Inspection of Markings Rescue boats which have been subjected to the production test with satisfactory result are to be marked with markings as specified in 7.3.3-4 in clear permanent characters.

7.7 Inflatable Liferafts

7.7.1 Liferaft Fittings and Equipment 1 Among the liferaft fittings and equipment, the following are to be of a type approved either by the flag government of the ship where they are carried, by contracting governments to the SOLAS Convention in force or by organizations recognized by these governments: (1) High pressure gas cylinders (including their valves); (2) External lamps; (3) Internal lamps; (4) Liferaft equipment:

(a) Thermal protective aids; (b) Food rations; (c) De-salting apparatus; (d) First-aid outfits; (e) Rocket parachute flares; (f) Buoyant smoke signals; (g) Hand flares;

(5) Retro-reflective materials; (6) Hydrostatic release units; (7) Weak links.

7.7.2 Type Approval 1 Drawings and documents to be submitted Drawings and documents to be submitted are specified in 7.2.1-1(2) to (5) and the following, each in triplicate: (1) Specifications; (2) General arrangements and construction (including air chamber construction, floor, canopy construction, water

pocket details and joint details for boarding ramps/ladders); (3) Liferaft fitting arrangement; (4) Liferaft equipment stowage and arrangement;


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(5) Gas charging arrangement; (6) Float-free arrangement; (7) List of materials used; (8) Carrying capacity calculation sheet; (9) Container construction; (10) Maintenance and inspection manuals; (11) Other drawings and documents which are deemed necessary by the Society. 2 Prototype Tests A prototype test is to consist of the following tests and inspections. The procedures for tests on material, strength and performance are to be in accordance with Chapter 1 “Procedures for Prototype Tests for Type Approval of Inflatable Liferafts” of Annex 3 “Procedures for Prototype Tests for Type Approval and Production Tests of Inflatable Liferafts”: (1) Material test:

(a) Test for materials for main buoyancy chambers, canopy supports, floors, floor buoyancy chambers and canopy;

(2) External and construction inspections: (a) External and construction inspection; (b) Dimension measurement; (c) Mass measurement; (d) Liferaft equipment inspection; (e) Marking inspection;

(3) Strength and performance tests: (a) Drop test; (b) Jump test; (c) Weight test; (d) Towing test; (e) Mooring out test; (f) Painter system test; (g) Loading and seating test; (h) Light load stability test; (i) Boarding test; (j) Stability test; (k) Manoeuvrability test; (l) Swamp test; (m) Canopy closure test; (n) Buoyancy of float-free liferafts; (o) Damage test; (p) Righting test; (q) Inflation test; (r) Pressure test; (s) Seam strength test; (t) Additional tests for davit-launched liferafts;

i) Strength test of lifting components ii) Impact test iii) Drop test iv) Boarding test v) Strength test

(u) Other performance tests; i) Air-charging test ii) Automatic lighting test

(v) Detailed inspection.

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7.7.3 Production Test 1 Inspection A production test is to consist of the examination of the implementation of the quality control system of the production site of the manufacturer and of the respective records, and of the following tests and inspections. The procedures for tests on strength and performance are to be in accordance with Chapter 2 “Procedures for Production Tests of Inflatable Liferafts” of Annex 3 “Procedures for Prototype Tests for Type Approval and Production Tests of Inflatable Liferafts”: (1) External and construction inspections:

(a) External and construction inspection; (b) Dimension measurement; (c) Mass measurement; (d) Liferaft equipment inspection; (e) Marking inspection;

(2) Strength and performance tests: (a) Inflation test (for inflatable liferafts selected by the Surveyor); (b) pressure and tightness test; (c) 10% overload test for davit-launched liferafts.

2 Inspections of Markings Inflatable liferafts which have been subjected to the production test with satisfactory result are to be marked with markings as specified in 7.3.3-4.

7.8 Launching Appliances for Lifeboats, Rescue Boats and Liferafts

7.8.1 Davit-launched Liferaft Automatic Release Hooks, Electric Appliances and Hydraulic Oil System 1 Davit-launched liferaft automatic release hooks are to be of a type approved either by the flag government of the ship where they are carried, by contracting governments to the SOLAS Convention in force or by organizations recognized by these governments. 2 Electric appliances of the launching appliances are to be in accordance with the requirements of Part H of the Rules. Motors and control boards may however be accepted if it is ascertained from the in-house test records of the respective manufacturers that they comply with the relevant requirements of Part H of the Rules or equivalent thereto. 3 Special materials, and special pipes of which working pressure exceeds 1.6 MPa of the hydraulic oil pressure system of the launching appliances are to be of those approved either by the Society or by organizations who are deemed appropriate by the Society.

7.8.2 Type Approval 1 Drawings and documents to be submitted Drawings and documents to be submitted are listed in 7.2.1-1(2) to (5) and the following, each in triplicate: (1) Specifications; (2) General arrangement; (3) Construction (including main dimensions, materials and joint details); (4) Strength calculations; (5) Winch specifications, performance and control mechanism; (6) Handling and maintenance manuals; (7) Other drawings and documents which are deemed necessary by the Society. 2 Prototype test A prototype test is to consist of the following tests and inspections. The procedures for tests on strength and performance are to be in accordance with Chapter 1 “Procedures for Prototype Tests for Type Approval of Launching Appliances” of Annex 4 “Procedures for Prototype Tests for Type Approval and Production Tests of Launching Appliances of Lifeboats, Rescue Boats and Liferafts”. (1) External and construction inspections:

(a) External and construction inspection;


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(b) Dimension measurement; (2) Strength and performance tests:

(a) Launching appliances of davits, etc.; i) Overload test ii) Swing-out test iii) Recovery operation test iv) Brake test v) Recovery test by rescue boat winches vi) Hand operation test of winches vii) Overhaul inspection of winches viii) Pressure test for hydraulic oil systems ix) Test for ramps for free-fall lifeboats x) Test for adjustable ramps

7.8.3 Production Test 1 Inspection A production test is to consist of the examination of the implementation of the quality control system of the production site of the manufacturer and of the respective records, and of the following tests and inspections. The procedures for tests on strength and performance are to be in accordance with Chapter 2 “Procedures for Production Tests of Launching Appliances” of Annex 4 “Procedures for Prototype Tests for Type Approval and Production Tests of Launching Appliances of Lifeboats, Rescue Boats and Liferafts”. (1) External and construction inspections:

(a) External and construction inspection; (b) Dimension measurement;

(2) Strength and performance tests: (a) Launching appliances with davit falls and winches;

i) Overload test ii) Pressure test of hydraulic oil systems iii) Non-destructive test for cast steel hooks of launching appliances for liferafts

2 Inspection of Markings Launching appliances which have been subjected to the production test with satisfactory result are to be marked with the following in addition to those as listed in 7.3.3-4: (1) Launching appliances including davits:

(a) Maximum working load ( maxL ); (b) Minimum working load ( minL );

(2) Winches: (a) Maximum working load ( maxW ).

7.9 Engines for Lifeboats and Rescue Boats (Including Reduction and Reversing Gears)

7.9.1 Type Approval 1 Drawings and documents to be submitted Drawings and documents to be submitted are listed in 7.2.1-1(2) to (5) and the following, each in triplicate: (1) Specifications; (2) Particulars; (3) General arrangement; (4) Sectional assembly plan; (5) Starting procedures; (6) List of materials used for main parts; (7) Engine installation plan / installation details; (8) Steering gear system of outboard motors; (9) Maintenance and inspection manuals;

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(10) Production records in past two years; (11) Other drawings and documents which are deemed necessary by the Society. 2 Prototype Test A prototype test is to consist of the following tests and inspections. The procedure for performance test is to be in accordance with Chapter 1 “Procedures for Prototype Tests for Type Approval of Engines for Lifeboats and Rescue Boats” of Annex 5 “Procedures for Prototype Tests for Type Approval and Production Tests of Engines for Lifeboats and Rescue Boats”: (1) External and construction inspections:

(a) External and construction inspection; (b) Dimension measurement; (c) Mass measurement;

(2) Performance tests: (a) Internal combustion engines (including reduction and reversing gears) for lifeboats and rescue boats

(excluding outboard motors); i) General performance tests

1) Starting test 2) No-load, low-speed operation test 3) No-load, high-speed operation test (in case where no speed governor is provided.) 4) Load test 5) Reversing operation/reverse operating test 6) Governor test (in case where a speed governor is provided.) 7) Charging test 8) Insulation resistance test 9) Endurance test

ii) Cold engine starting test iii) Engine-out-of-water test iv) Submerged engine test v) Additional tests for engines for self-righting partially enclosed, totally enclosed, lifeboats with a

self-contained air support and fire-protected lifeboats 1) Engine inversion test

vi) Overhaul inspection (b) Overboard motors for rescue boats;

i) General performance tests 1) Starting test 2) No-load, low-speed operation test 3) No-load, high-speed test (in case where no speed governor is provided.) 4) Full load test 5) Minimum speed operating test 6) Reversing operation and reverse operating test 7) Governor test (in case where a speed governor is provided.) 8) Quick speed changing test 9) Engine-out-of-water test 10) Charging test 11) Insulation resistance test 12) Endurance test

ii) Tests for rescue boats 1) Running test 2) Water drench test 3) Hot start test 4) Manual start test 5) Cold start test

iii) Overhaul inspection


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7.9.2 Production Test 1 Inspection A production test is to consist of the examination of the implementation of the quality control system of the production site of the manufacturer and of the respective records, and of the following tests and inspections. The procedures for performance tests are to be in accordance with Chapter 2 “Procedures for Production Tests of Engines for Lifeboats and Rescue Boats” of Annex 5 “Procedures for Prototype Tests for Type Approval and Production Tests of Engines for Lifeboats and Rescue Boats”: (1) External and construction inspections:

(a) External and construction inspection; (b) Dimension measurement; (c) Mass measurement;

(2) Performance tests: (a) Internal combustion engines (including reduction and reversing gears) for lifeboats and rescue boats

(excluding outboard motors); i) Starting test ii) No-load, low-speed operating test iii) No-load, high-speed operating (in case where no speed governor is provided.) iv) Load test v) Reversing operation and reversing test vi) Governor test (in case where a speed governor is provided.) vii) Charging test viii) Insulation resistance test ix) Overhaul inspection

(b) Outboard motors for rescue boats; i) Starting test ii) No-load, high-speed operating test (in case where no speed governors is provided.) iii) Full load test iv) Minimum speed operating test v) Reversing operation and reversing test vi) Governor test (in case where a speed governor is provided.) vii) Charging test viii) insulation resistance test ix) Overhaul inspection

2 Inspection of Marking Engines which have been subjected to the production test with satisfactory result are to be marked with the following in addition to those as specified in 7.3.3-4. (1) maximum continuous output and rotation

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Form 2-6

Notes:

1. Use additional sheets if necessary 2. Tick off where appropriate


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Form 2-7

Notes:

1. Use additional sheets if necessary. 2. Tick off where appropriate.

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Form 2-8

Notes:

1. Society examines and returns the application with approval stamp. 2. This application is to be submitted in triplicate.


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Chapter 8 SEWAGE TREATMENT PLANT AND SEWAGE COMMINUTING AND DISINFECTING SYSTEM

8.1 General

8.1.1 Scope The requirements of this chapter apply to testing and inspection for the approval of use of a sewage treatment plant (hereinafter referred to as a “plant” in this chapter) and a sewage comminuting and disinfecting system (hereinafter referred to as a “system” in this chapter) on ships in accordance with the requirements of 2.2.1-1 and -2, Part 7 of Guidance for Marine Pollution Prevention Systems.

8.2 Application

8.2.1 Application Form The manufacturer, who intends to obtain the approval of use, is to submit an application (Specimen Form 2-9) filled in with necessary data and information to the Society (Head Office).

8.2.2 Documents 1 The documents listed (1) through (9) below, each in triplicate, are to be submitted together with the application form specified in 8.2.1. (1) Introduction of the manufacturing plant (2) Product quality assurance system implemented (3) Records of manufacture and delivery of the product (4) Complete description of the product (5) Construction drawings with all dimensions necessary for evaluation of the product (6) Drawings used for main components provided with their materials (7) Manuals for installation, operation and maintenance of the product (8) Approval test plan (provided with the place and scheduled date of test) (9) Test records (if any preliminary test is carried out) (10) Other documents which are considered necessary by the Society 2 Notwithstanding the requirements in -1 above, submission of part or all of the documents may be omitted if the manufacturer had previously obtained the approval from the Society in the past, and the duplicated items are included therein.

8.3 Confirmation Survey of Manufacturing Factory

8.3.1 Confirmation Survey of Manufacturing Factory The Society may carry out confirmation survey on facilities, manufacturing techniques, product quality control and internal inspection of the manufacturing factory based on the data specified in 8.2 in order to verify the factory's ability of manufacturing product of stable quality.

8.4 Approval Tests for Sewage Treatment Plant

8.4.1 Items of Prototype Test Items of prototype test are as follows: (1) Effluent test (2) Operation test (3) Tilt and vibration test (4) Other tests as considered necessary by the Society

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8.4.2 Effluent Test 1 The influent is to be fresh sewage consisting of faecal matter, urine, toilet paper and flush water to which primary sewage sludge has been added as necessary to attain a minimum concentration of 500 mg/l of suspended solids. 2 The duration of the test period is to be 10 days after steady-state conditions have been reached by the equipment under test. 3 The plant is to be installed in accordance with the manufacturer’s specification and in a manner which facilitates the collection of samples, and is to be tested following zero, maximum, minimum and average volumetric loading. 4 A minimum of 40 samples are to be collected from influent and effluent at intervals exceeding 2 hours, but 4 times/day. Any disinfectant residual in samples is to be neutralized when the sample is collected. 5 The effluent is to be inspected as follows: (1) Faecal Coliform

The faecal coliform is to be counted from the sample and the geometric mean of it is to be calculated from the counts and is not to exceed 250 faecal coliforms/100 ml M.P.N as determined by a multiple tube fermentation. The analytical procedure is to be in accordance with JIS K 0430-72-40 or an equivalent.

(2) Suspended Solids (SS) The geometric mean of the total suspended solids is to be calculated in accordance with (i) above and is not to exceed 100 mg/l. The analytical procedure is to be in accordance with JIS K 0102 or an equivalent.

(3) 5-day Biochemical Oxygen Demand (BOD5) The geometric mean of the 5-day biochemical oxygen demand is to be calculated in accordance with (i) above and is not to exceed 50 mg/l. The analytical procedure is to be in accordance with JIS K 0102 or an equivalent.

6 The name and quantity of the neutralizer are to be recorded during the test where chlorine or its compounds are used as disinfectant. 7 The effluent is to satisfy the following conditions: (1) Visible floating solids are not to be produced. (2) Discoloration of the surrounding water is not to be caused.

8.4.3 Performance Test Performance tests are to be carried out over the range of temperature and salinity specified by the manufacturers that operating characteristics are satisfactory.

8.4.4 Tilt and Vibration Test 1 It is to be confirmed that no abnormality is observed when the plant is at an operating condition under 15 degrees static inclination. For large plants, this test may be substituted for an ideal test on the drawings by inclining the highest water level up to 15 degrees. 2 Electronic apparatus used for the plant are to be subject to the vibration test of which conditions are specified in Table 2.8-1 and Table 2.8-2 and to the following tests after vibration test. (1) Performance tests of the apparatus (2) Insulation resistance test between the current-carrying parts and between the current-carrying parts entirely

connected each other and the earth, the result of which is not to be less than 1 MΩ upon applying at least DC 500 V.

Table 2.8-1 Resonance Test Condition

Amplitude or Acceleration

Frequency Sweep time Directions Cycles Total test time

2 mm 2 Hz～13.2 Hz 10 minutes 3 axis directions3 cycles for each

directions 1.5 hours

±0.7g 13.2 Hz～80Hz Ditto Ditto Ditto Ditto


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Table 2.8-2 Endurance Test Condition Amplitude or

Acceleration Frequency Directions Cycles Total test time

When resonance points exist on the

test specified in Table 2.8-1

Same Amplitude or Acceleration

of the test specified in Table 2.8-1

Resonance points 3 axis directions 1 cycle for each

directions 4.5 hours

When resonance points do not exist

on the test specified in Table

2.8-1

2 mm 13.2 Hz Ditto Ditto Ditto

8.5 Approval Tests for Sewage Comminuting and Disinfecting System

8.5.1 Approval Tests for Sewage Comminuting and Disinfecting System 1 The system is to be installed in accordance with 8.4.2-3. 2 Vibration test It is to be confirmed that no abnormality is observed during the vibration test of which conditions are specified in Table 2.8-1 and Table 2.8-2. 3 Function tests (1) Visual inspection (2) Capacity test

The treating capacity is to be confirmed not less than the flow rate provided in the manufacturer's specification by measuring the influent specified in 8.4.2-1 being delivered continuously at minimum pressure or minimum flow rate specified by the manufacturers.

(3) Hydrostatic test For the seal of the shaft, a hydrostatic test is carried out at 10 kPa for 10 minutes.

(4) Operation test It is to be confirmed that the system is in good working condition wherein no abnormality is observed and no solidity of 25mm or more in size is contained in the effluent, and no uncomminuted influent is left in the system by the operation using the influent specified in 8.4.2-1. At the same time, the disinfecting system is to be operated to confirm its disinfecting function that the faecal coliform counted by the method specified in 8.4.2-5(1) is not to exceed 3000 faecal coliforms/ml M.P.N.

(5) Overload protection test It is to be confirmed that the power can not be supplied when the system is started under the condition the cutting blade is fixed and that the system can not be started automatically when the power supply is restored upon the blade being released. No abnormality is to be observed during the test.

(6) Noise test After the system is rigidly fixed, the noise level is to be measured in normal operating condition without any influent. The noise level is to be 80 dB(A) or less at a distance of 1 m or more.

(7) Insulation resistance test The insulation resistance test between current-carrying parts entirely connected each other and the earth and between current-carrying parts of each opposite polarity or phase are not to be less than 10 MΩ upon applying at least DC 500 V.

(8) High voltage test The high voltage test is to be carried out at the following voltage for one minute between current-carrying parts entirely connected each other and the earth and between current-carrying parts of each opposite polarity or phase. Instruments and auxiliary apparatus, if any, may be disconnected during the test:

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For rated voltage of 60 V or less: 500 V For rated voltage exceeding 60 V: 1,000 V + twice the rated voltage (minimum 1,500 V)

(9) Power supply fluctuation test It is to be confirmed that no abnormality is observed and no solidity is contained in the effluent, and no uncomminuted influent is left in the system by the operation using the influent specified in 8.4.2-1 when the power supply is kept fluctuating from +10% to -10% of the rated power. For electrical power supply, both the rated voltage and the rated frequency are to be fluctuated from +10% to -10% and +5% to -5% respectively.

4 Other tests as considered necessary by the Society

8.6 Approval

8.6.1 Test Records The manufacturer is to prepare records of the approval test after completion of the test, to obtain verification by the Society’s attending surveyor and to submit them, in triplicate, to the Society.

8.6.2 Notification of Approval The Society, when satisfied upon examination of the submitted documents and the attending surveyor’s report, will issue a certificate of approval specifying the approval number, approval date, items of approval and approval conditions, put approval stamps on the documents as deemed necessary by the Society out of those submitted in accordance with 8.2 and 8.6.1, and return them back to the applicant.

8.6.3 Renewal of Approval 1 The valid term of the approval in the preceding 8.6.2 will be 5 years. 2 In case where renewal of the validity is intended, the manufacturer is to submit the necessary documents together with the existing certificate in accordance with the requirements of 8.2 newly. In this case, the documents specified in 8.2 may be limited to the portion subjected to modification only. 3 When approval has been granted to an application with partial changes in the content of approval, the Society may require additional tests for approval.

8.6.4 Revocation of Approval In case where either of the following (1) to (4) applies, the Society will revoke the type approval and give notice to the manufacturer. (1) In association with the implementation or revision of international conventions, laws, and regulations, the plant

or system for which the approval was granted do not deserve the approval any longer. (2) In case where the validity of approval is overdue and no application for the renewal of the approval is submitted. (3) When serious shortcomings are found in structure or quality of the plant or system already approved after being

installed ships. (4) When an applications for revocation is made by the manufacturer.

8.7 Examinations for Products

8.7.1 Examinations for Products For each component of a plant/system supplied to an individual ship after obtaining approval by the Society, the following tests and examinations are to be carried out under the presence of the Surveyor in order to confirm that the products has been manufactured in the same specification as those used for the approval test of the plant/system. However, where the quality management system of the manufactures who produce each component of the plant/system is one to the satisfaction of the Society, the frequency of the Surveyor's attendance for the examination of the product may be reduced based upon the provision in B2.1.4-5 of the Guidance for the Survey and Construction of Steel Ships. (1) Visual inspection (2) Dimensional inspection and examination of construction (3) Performance tests of the safety devices, alarms and inter-locking device (4) Insulation resistance test specified in 8.4.4-2(2) or 8.5.1-3(7)


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(5) High voltage test specified in 8.5.1-3(8) (to be also applied to a plant) (6) Hydrostatic tests at the pressure of 2 times for the design pressure for tanks subject to internal pressure and at the

pressure of 0.25 MPa above the top of the tank for the other tanks (to be applied to a plant only) (7) Other tests as considered necessary by the Society

8.8 Announcement of Approval

8.8.1 Announcement of Approval The plant/system approved by the Society are to be marked with the following. (1) Type and model of the product (2) Mark to prove that the product is approved by the Society. It may be marked simply by NK. (3) Name of the manufacturer (4) Approval number

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Form 2-9

Notes:

1. Use additional sheets if necessary. 2. Tick off where appropriate.


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Part 3 WELDING CONSUMABLES

Chapter 1 APPROVAL OF WELDING CONSUMABLES

1.1 General

1.1.1 Scope In accordance with the requirements in 6.1.3 and 6.1.4, Part M of Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”), the requirements in this chapter apply to tests and inspection for the purpose of treating welding consumables as approved welding consumables.


1.2.1 Approval Application Form Manufacturers wishing to obtain approval are to submit to the Society (Branch Office) a single copy of the Approval Application Form (Specimen Form 3-1), which includes for each manufacturing plant the brands of the welding consumables (for submerged arc welding consumables, each brand of core wire and combination flux), kind, symbol, purpose, maximum core wire diameter produced and the maximum quantity hydrogen (this is limited to non-low-hydrogen electrodes for high tensile sheets), together with two copies each of documents and data specified in 1.2.3.

1.2.2 Approval Applicant The approval applicant is, as a rule, to be the manufacturer of welding consumables. However, the applicant need not always be the manufacturer of the welding consumables if this applicant is ultimately responsible for the quality assurance of the welding consumables and possesses the ability to perform approval tests and Annual Inspection.

1.2.3 Data to be Submitted 1 Data to be submitted together with Approval Application Form are as follows : (1) Outline of manufacturing plant (2) Major manufacturing facilities (3) Inspection standards and inspection equipment (4) Inspection division and claim handling division (5) The following data related to manufacturing process and quality control :

In the case of covered electrodes: (a) Data on type acceptance criteria, wire drawing method, cutting and rust protection of core wire (b) Data on type protection of main components, shattering, mixing and churning of coating, flux (c) Data on coating method, off-centering and drying methods (d) Data on final processing

In the case other than covered electrodes (e) Data on chemical composition, manufacturing process, acceptance criteria, wire drawing method and rust

protection of core wire (f) Data on main composition, manufacturing process, grain size distribution, etc. of flux

(6) Data on storage method (7) Data on packaging marking (8) Recent test records, or experiments and research data on welding consumables for which approval is desired (9) Data on the content of warning if they are provided against usage such as proper current range, etc. (10) In case of non-low hydrogen electrodes for high tensile steels, data on antirestrained crack tests such as the

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restrained fillet crack test carried out at the maximum quantity of hydrogen noted in the application. (11) Other data seemed necessary by the Society 2 Notwithstanding the requirements in preceding -1, part or all of the reference data may be exempted from submission when record of approval by the Society is available and the data is found consistent with the data submitted at that time.


1.3.1 Confirmation Survey of Manufacturing and Quality Control Procedure Confirmation survey of manufacturing and quality control procedure is to be carried out to verify, on the basis of the data specified preceding 1.2.3, whether the manufacturer has the capability (facilities, technology, quality control and inspection system) to manufacture welding consumables, under stable operation uniformly and continuously with a quality equivalent to or better than that of welding consumables subjected to the approval test.

1.3.2 Items to be Confirmed The confirmation survey shall be conducted on the following items : (1) Whether or not the company inspection department and department responsible for the settlement of claims are

well organized. (2) Whether or not the factory facilities and inspection facilities are well equipped. (3) Whether or not various specifications, work standards and quality control schemes are well organized and

functioning.

1.3.3 Omission of Confirmation Survey 1 In cases when the welding material submitted for approval is manufactured by the same facilities and similar manufacturing procedure as for the welding material already approved, confirmation survey may be omitted and examination of documents of revised items in manufacturing procedure only shall be conducted. 2 For a factory who has been manufacturing core wire of covered electrode under the approval of the Society, confirmation survey on manufacturing and drawing process of wire may be omitted for automatic welding wires.

1.4 Approval Tests

1.4.1 Approval Test 1 Approval tests is to, in principle, be conducted at the manufacturing plant in the presence of the surveyor of the Society. 2 Approval test is to be conducted using the welding consumables taken at random by the surveyor.

1.4.2 Contents of Approval Tests Contents of the approval tests are to be in accordance with the requirements in 6.2 through 6.8, Part M of the Rules except the following (1) and (2). (1) When a part of the approval tests are exempted under the provisions of 6.1.3-4 or 6.1.3-5, Part M of the Rules,

approval tests are to be done in accordance with the requirements of 1.10 of this chapter. (2) Approval tests are to be done in accordance with the requirements of 1.11 of this chapter for the welding

consumables, to which the provisions 6.1.3-3, Part M of the Rules has been applied.

1.4.3 Test Records After completion of the approval test, the manufacturer is to produce records of approval test and is to submit three copies of them to the Society (Branch Office) upon receiving confirmation by the attending surveyor.

1.5 Approval

1.5.1 Notification and Announcement of Approval 1 The Society examines the submitted test record and results of confirmation survey, and if found satisfactory, the welding consumables shall be approved and an approval certificate shall be issued to each brand. The date of issue of the approval certificate is to be coincided with the date of completion of the approval test.


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2 Once a year, the Society announces approved welding materials in a form of a table.

1.5.2 Term of Validity The certificate of approval shall be valid for one year from the date of issue.

1.6 Annual Inspection

1.6.1 Application for Annual Inspection The each manufacturing plant who requests annual inspection is to be submitted an application for annual inspection for approved welding consumables (Form 3-2, any convenient form, however, may be accepted for the annual inspection of multiple brands of welding consumables) to the Society (Branch Office) within the term of validity of the certificate.

1.6.2 Items to be Covered by Annual Inspection 1 The annual inspection is to, in principle, be conducted at the manufacturing plant in the presence of the Surveyor of the Society. 2 The confirmation survey in annual inspection is to be conducted in accordance with 1.3 of this Chapter. 3 The test in annual inspection is to be conducted in accordance with the requirements of 6.1.5, Part M of the Rules using the welding consumables taken at random by the Surveyor of the Society.

However, the test in annual inspection is to be done in accordance with the requirements of 1.11 of this chapter for the welding consumable, to which the provisions 6.1.3-3, Part M of the Rules has been applied. 4 The annual inspection is to be completed within the effective period of the approval certificate. However, for unavoidable circumstances, the annual inspection may be completed within a period of 3 months after the expiration date upon the approval by the Society.

1.6.3 Test Records After completion of the test in annual inspection, the manufacturer is to prepare two copies of test reports and submit them to the Society (Branch Office) upon receiving confirmation by the attending surveyor.

1.6.4 Renewal of Validity of the Approval Certificate 1 The Society will make renewal the validity of the certificates for approved welding consumables which have passed the annual inspection. 2 The validity shall be for one year from the next day after the expiry date of the previous validity. 3 In case of the annual inspection has passed earlier than three months prior to the expiry date of the previous certificate, the new expiry date may be fixed, at the request of the applicant, before the date obtained by the provision of the preceding -2.

1.7 Change in the Approval Content

1.7.1 Application for Change 1 In case when the particulars of the welding consumables which being mentioned in the certificate of approval, such as grade, welding position, maximum diameter of electrodes or shield gas, is changed, the manufacturer is to submit a single copy of application form for change together with two copies of necessary data to the Society (Branch Office), and necessary additional approval tests are to be carried out accordingly. 2 When the significant changes in compositions or manufacturing process of the wire and flux or removal of manufacturing plant is made, the manufacturer is to submit a single copy of notification of alternation in any preferred form together with three copies of necessary data to the Society (Branch Office), and necessary confirmation survey and test may be carried out accordingly.

1.7.2 Content of the Tests 1 Approval tests and confirmation tests are to, in principle, be conducted at the manufacturing plant in the presence of the surveyor. 2 The additional approval tests under the provision of 1.7.1-1 aforementioned, are to be done in accordance with the followings :

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(1) Change of Grade The additional tests are to be done in accordance with the requirements of 6.1.3-6, Part M of the Rules.

(2) Addition of Welding Position Tests, of which test assemblies are specified to be prepared for additional welding positions in the provisions of 6.2 through 6.8, Part M of the Rules, are to be done.

(3) Enlargement of Maximum diameter of Electrode or Wire Tests required to be tested at the largest diameter electrode or wire under the provisions of 6.2 through 6.8, Part M of the Rules.

(4) Addition of Shield Gas Additional tests are to be done in accordance with the requirements of 6.3.3, 6.4.3, and 6.7.3, Part M of the Rules.

(5) Others As deemed necessary, the test required by the Society basing on the nature and extent of the change, are to be done.

3 When confirmation test is required under the provision of 1.7.1-2, the details of the confirmation test is to be informed by the Society taking consideration of the nature and extent of the changes.

1.7.3 Test Record and Certificate of Approval 1 Test record is to be submitted to the Society as follows: (1) Approval test record is to be submitted in accordance with the provisions of 1.4.2. (2) Confirmation test record is to be submitted in accordance with the provision of 1.6.3. 2 In case when items described in the certificate of approval is changed, the manufacturer is to return the certificate to the Society (Branch Office).

1.7.4 Rewrite of the Approval Certificate The Society shall make correction on the altered items in the certificate, if deemed appropriate, upon studying the submitted data from the manufacturer, results of confirmation survey and/or test record.

1.8 Revocation of Approval and Reapproval

1.8.1 Revocation of Approval 1 When question arises on the quality of approved welding consumables from its uses, the Society shall require the manufacturer necessary investigation and/or improvement of the quality. When the Society considers it necessary, the confirmation test on the selected items is to be conducted in the presence of the surveyor. 2 In case any of the following (1) through (4) is relevant, the Society may revoke approval of the welding consumables and give notice of the revocation to the manufacturer except case (3) or case (4). (1) When confirmation test results mentioned in -1 above shows unsatisfactory for the approved consumables. (2) When the annual inspection is failed. (3) When the approved welding consumable is not subjected to the annual inspection. (4) When a request of revocation is made by the manufacturer. 3 The manufacturer who received the notice of revocation or requested revocation has to return the certificate of approval to the Society (Branch Office) immediately.

1.8.2 Reapproval Reapproval of the welding consumables which was revoked by the request of the manufacturer is to be done in accordance with the provisions of 1.2 through 1.5. In case of no major change of manufacturing process, quality control process from the time of previous approval, the extent of the approval test may be reduced to the annual test level.

1.9 Packing and Marking

1.9.1 Packing and Marking The manufacturers are to be specially noted the following points on the packing and marking of the approved


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welding materials. (1) The approved welding materials are to be packed thoroughly to keep the quality during their transportation and

storage. (2) All boxes or packages of the approved welding consumables are to be clearly marked with the following

descriptions together with the mark of approval by the Society. (a) Brand (b) Name or mark of Manufacturer and manufacturing plant (c) Grade or mark of welding consumables (d) Kind of gas where it is used (e) Electric current and its polarity (f) Welding position (g) Date and number of production (h) Size (diameter of core wire, length of electrode, grain size of flux for automatic submerged arc welding,

etc.)

1.10 Reduction of Approval Test for the Same Brand of Approved Consumables

1.10.1 In case when the manufacturer request reduction of part of approval test under the provisions of 6.1.3-4 and -5, Part M of the Rules, the manufacturer is to submit an application form (specimen Form 3-1) with descriptions for this reduction and three copies of the following data to the Society (Head office). (1) Approval test plan (2) Data mentioned in preceding 1.2.3-1. However, the contents of in-company test specified in 1.2.3-1(8) is to be in

accordance with the requirements of 6.2 through 6.8, Part M of the Rules. (3) Verification data showing the requested consumables identified as the approved consumables manufactured by

the other plant (4) Copy of the approval certificate for the welding consumables being issued for the other plant (5) Data on licence (in case where the provisions of 6.1.3-5, Part M of the Rules being applied)

1.10.2 The society studies the application and data being submitted and, if deemed appropriate, may permit the reduced approval test at least equivalent to annual test. In this case the approval test plan will be approved and returned to the manufacturer.

1.11 Approval Test and Annual Inspection for Welding Consumables which are not Specified in the Rules

1.11.1 Approval Test 1 The manufacturer, who wishes the approval of welding consumables to which the provisions in 6.1.3-3, Part M of the Rules has been applied, is to submit an application form (see Form 3-1) and three copies of the following data to the Society (Head office). (1) Approval test plan including test procedure and testing items (2) Data on the specification to be applied to the welding consumables (3) Data specified in preceding 1.2.3. 2 The Society (Head office) studies the application and data submitted and, if deemed appropriate, approve the test plan return it to the manufacturer. 3 The approved test is to be conducted in accordance with the approval plan.

1.11.2 Annual Inspection Annual inspection for the welding consumables specified in preceduring 1.11.1, is to be conducted in accordance with the test plan which deemed appropriate by the Society.

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Form 3-1


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Form 3-2

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Part 4 NON-METALLIC MATERIALS AND COATING MATERIALS FOR HULL

Chapter 1 APPROVAL OF FIRE PROTECTION MATERIALS

1.1 General

1.1.1 Scope The requirements of this Chapter apply to the tests and inspections for the approval of fire protection material specified in (1) through (9) below in accordance with the requirements of Part R of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”). (1) Non-combustible materials (2) “A” class divisions (3) “B” class divisions (4) Continuous “B” class divisions (5) Fire retardant base materials (6) Fire retardant veneers (7) Fire retardant surface floorings (8) Primary deck coverings (9) Fire retardant coatings

1.2 Definitions

1.2.1 Non-Combustible Materials “Non-combustible materials” are the materials defined in 3.2.33, Part R of the Rules.

1.2.2 “A” Class Divisions 1 “A” class divisions are the divisions defined in 3.2.2, Part R of the Rules. 2 “A” class divisions are classified into four ratings according to temperature conditions : “A-60” rating, “A-30” rating, “A-15” rating and “A-0” rating. They are classified into seven kinds according to their applications as follows: (1) Bulkheads (2) Decks (3) Fire-retardant doors (4) Windows (5) Fire dampers (6) Pipe and duct penetrations (7) Cable penetrations

1.2.3 “B” Class Divisions 1 “B” class divisions are the divisions defined in 3.2.4, Part R of the Rules. 2 “B” class divisions are classified into two ratings according to temperature conditions : “B-15” rating and “B-0” rating. They are classified into nine kinds according to their applications as follows: (1) Bulkheads (2) Decks (3) Fire-retardant doors (4) Linings (5) Ceilings (6) Windows (7) Fire dampers


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(8) Pipe and duct penetrations (9) Cable penetrations

1.2.4 Continuous “B” Class Divisions 1 “Continuous “B”class divisions” are the divisions defined in 3.2.16, Part R of the Rules. 2 Continuous “B” class divisions are classified into two ratings according to temperature conditions : “B-15” rating and “B-0” rating. They are classified into two kinds according to their applications as follows: (1) Continuous linings (2) Continuous ceilings

1.2.5 Fire Retardant Base Materials 1 “Fire retardant base materials” are the combustible materials used for internal divisions, linings, draft stops, ceilings, their associated grounds within accommodation and service areas of a ship adopting Method IIC or IIIC specified in 9.2.2-1, Part R of the Rules. 2 Fire retardant base materials are classified into two kinds according to their applications as follows: (1) Fire retardant base materials for Divisions:

Materials used for ceilings, linings or draft stops, etc. (2) Fire retardant base materials for Grounds:

Materials used for grounds

1.2.6 Fire Retardant Veneers 1 “Fire retardant veneers” are the combustible veneer materials applied on internal exposed surfaces and on surfaces in concealed or inaccessible spaces in a ship except floors. 2 Fire retardant veneers are classified into three kinds according to the kinds of applied base material as follows: (1) Fire retardant veneers for Non-combustible and Fire retardant base materials:

Veneers suitable to be applied on either of both non-combustible base materials (base materials made of non-combustible materials; The same is to apply hereinafter.) or fire retardant base materials.

(2) Fire retardant veneers for Non-combustible base materials: Veneers limited to be applied on non-combustible base materials

(3) Fire retardant veneers for Fire retardant base materials: Veneer limited to be applied on fire retardant base materials

1.2.7 Fire Retardant Surface Floorings “Fire retardant surface floorings” are the combustible materials applied on floor surfaces in a ship.

1.2.8 Primary Deck Coverings “Primary deck Coverings” are portions of materials excluding forming a deck excluding “A” class decks which include thermal insulation materials and fire retardant surface floorings.

1.2.9 Fire Retardant Coatings 1 “Fire retardant coatings” are the finishing materials applied on the exposed surfaces in a ship. 2 Fire retardant coatings are classified into the followings: (1) Alkyd resin coating (2) Chlorinated rubber coating (3) Tar epoxy resin coating (4) Denatured epoxy resin coating (5) Pure epoxy resin coating (6) Urethane resin coating (7) Emulsion coating (8) Water gross coating (9) Polyvinyl chloride resin coating (10) Pure silicone coating (11) Others

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1.2.10 Fire-Resisting Devisions for High-Speed Craft “Fire-resisting materials for high-speed craft” are the devisions specified in 1.2.2, Part 11 of the Rules for High Speed Craft.

1.2.11 Fire-Restricting Materials for High-Speed Craft “Fire-restricting materials for high-speed craft” are the materials specified in 1.2.3, Part 11 of the Rules for High Speed Craft.

1.2.12 FTP Code “FTP Code” means the “International Code for Application of Fire Test Procedures” as adopted by the Maritime Safety Committee of the International Maritime Organizations by the Resolution MSC.61(67), as amended. In applying “FTP Code”, the following requirements are to be complied with. (1) Section 3.2.3 of IMO Resolution A.754(18)

Adhesives used in “A” class divisions are not required to be non-combustible, however, they are to be low flame spread.

(2) Section 5.1 of IMO Resolution A.754(18) In cases where a test specimen (deck) which includes the prototype penetration is not mounted within a rigid restraint frame but is connected to the furnace roof by side wall coamings, the rigidity of the coamings is to be equivalent to that of a restraint frame and evaluated in accordance with Section 5.1of IMO Resolution A.754(18).

(3) Appendix.III/2.2.3 of IMO Resolution A.754(18) In cases where insulation is fitted to the test pipe, the distance of 500 mm required in A.III/2.2.3 of IMO Resolution A.754 to which the pipe is to project is to be taken from the end of the insulation as this is considered an integral part of the penetration being tested and it is necessary that a length of unprotected pipe is exposed to the furnace.

(4) Appendix.III/2.2.4 of IMO Resolution A.754(18) The support and fixing of the test pipe are to be by a framework mounted from the restraint frames such that any movement of the bulkhead or deck relative to the pipe is experienced by the penetration being tested.

1.3 Requirements

1.3.1 Non-Combustible Materials The test procedures for non-combustible materials are in accordance with “Non-Combustibility Test” specified in 1.13.1.

1.3.2 “A” Class Divisions 1 The test procedures for “A” class divisions are in accordance with “Test for “A” and “B” Class Divisions” specified in 1.13.3. 2 The materials constituting “A” class divisions are to be made of non-combustible material specified in 1.2.1 except adhesives. For approval, the certificates issued by the Society or the test results of fire tests, non-combustibility test and test for surface flammability are to be submitted.

1.3.3 “B” Class Divisions 1 The test procedures for “B” class divisions are in accordance with the provisions specified in 1.3.2-1. 2 The materials constituting “B” class divisions are in accordance with the provisions specified in 1.3.2-2. However, combustible veneers may be permitted as a portion of the division provided that they are tested in accordance with “Smoke and Toxicity Test” and “Test for Surface Flammability” specified in 1.13.2 and 1.13.5 respectively.

1.3.4 Continuous “B” Class Divisions 1 The test procedures for continuous “B” class divisions are in accordance with “Test for Continuous “B” Class Divisions” specified in 1.13.4. 2 The materials constituting continuous “B” class divisions are in accordance with the provisions specified in 1.3.2-2.


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1.3.5 Fire Retardant Base Materials The test procedures for fire retardant materials are in accordance with “Smoke and Toxicity Test” and “Test for Surface Flammability” specified in 1.13.2 and 1.13.5 respectively.

1.3.6 Fire Retardant Veneers 1 The test procedures for fire retardant veneers are in accordance with the provisions specified 1.3.5. 2 The calorific value of fire retardant veneers fitted on the surfaced of non-combustible materials does not exceed 45 MJ/m2 for the thickness used.

1.3.7 Fire Retardant Surface Floorings The test procedures for fire retardant surface floorings are in accordance with the provisions specified in 1.3.5.

1.3.8 Primary Deck Coverings The test procedures for primary deck coverings are in accordance with “Test for Primary Deck Coverings” specified in 1.13.6.

1.3.9 Fire Retardant Coatings 1 The approval of fire retardant coatings is made to actual coating systems, taking into consideration of the combination of the under coating and the to coating, on the basis of the coatings classified according to the kinds of synthetic resins used. 2 The test procedures for fire retardant coatings are in accordance with the provisions specified in 1.3.5. The tests are conducted to a combination which provides the maximum quantity of organic material in the coating system used. 3 When inorganic coatings are used for under coatings, only the coatings system with top coatings of organic materials is the subject of approval.

1.3.10 Fire-Resisting Divisions for High-Speed Craft The test procedures for fire-resisting divisions for high-speed craft are to be in accordance with “Fire-Resisting Divisions” specified in 1.13.8.

1.3.11 Fire-Restricting Materials for High-Speed Craft The test procedures for fire-restricting materials for high-speed craft are to be in accordance with “Fire-Restricting Materials” specified in 1.13.7.

1.4 Application Procedure for Approval

1.4.1 Application Form for Approval 1 When obtaining the approval of fire protection materials except fire retardant coatings, an application for approval (Specimen Form 4-1) accompanied by the documents specified in 1.4.3-1 (one for each item) is submitted to the Society (Head Office). 2 When obtaining the approval for fire retardant coatings, an application for approval (Specimen Form 4-2) accompanied by the documents specified in 1.4.3-2 (one for each item) is submitted to the Society (Head Office).

1.4.2 Applicant for Approval The applicant for approval is, in principle, to be the manufacturers of materials, but any person who is responsible ultimately for the quality of the material may be regarded as the applicant.

1.4.3 Submission of Attached Documents to the Application 1 When obtaining the approval of fire protection materials other than fire retardant coatings, the documents including the following data are submitted to the Society together with the application specified in 1.4.1: (1) Historical record of the company (2) Outline of the facilities of works (3) If applicable, the documents (a copy of the certificate or the document of compliance) on Quality control system

of the company (both of the applicant and the manufacturer) (4) Kinds of materials (names and trade names of the materials specified in 1.1 and 1.2) (5) Constituent materials and their properties (6) Specifications of the products (including detail drawings)

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(7) Test report of the required fire tests specified in 1.3.1 through 1.3.11 (8) Records of service (9) Marking (label, etc.) (10) Other items which the Society considers necessary 2 When obtaining the approval of fire retardant coatings, the documents including the following data are submitted to the Society together with the application specified in 1.4.1: (1) Historical record of the company (2) Outline of the facilities of works (3) If applicable, the documents (a copy of the certificate or the document of compliance) on quality control system

of the companies (both of the applicant and the manufacturer) (4) Kinds of materials (names and trade names of the materials specified in 1.1 and 1.2) (5) List of coating system (Specimen Form 4-5) (6) Table of chemical composition (7) Test report of the required fire tests specified in 1.3.9 (including actual coating condition and dry film thickness

of the test specimen) (8) Records of service (9) Marking (label, etc.) (10) Other items which the Society considers necessary 3 The table of chemical composition required in -2(6) above provides organic and inorganic components separately so that organic substance can be estimated. 4 The test reports required in -1(7) and -2(7) above are an original or a duplicate copy issued by a testing laboratory specified in 1.6.1-1.

1.4.4 Omission of Accompanying Data 1 Data for constituent materials, process of manufacture, work standards, etc. which are considered secret to the manufacturer may be exempted from submission subject to the statement to that effect. These data, however, may be required if the Society considers necessary. 2 The data of historical record of the company, outline of facilities of works, method of quality control, method of quality assurance, etc. which are the same in content as those submitted on the occasion of the approval of other materials need not to be submitted. These data, however, may be required if the Society considers necessary. 3 When the manufacturer desires to be exempted from submission of those data, an application stating the reasons thereof are submitted.


1.5.1 Confirmation of Manufacturing and Quality Control Procedure 1 The confirmatory survey of manufacturing and quality control procedure is carried out after examination of the documents submitted for the application for approval. However, this confirmation survey may be omitted where deemed appropriate by the Society. 2 The confirmatory survey of manufacturing and quality control procedure is carried out to examine whether the manufacturer has the sufficient capability (facilities, staffs, engineering, etc.) to manufacture the materials applied for approval continuously with a stable quality level. 3 The confirmatory survey may be omitted if the materials are being manufactured in the same facilities and in the process considered almost the same as those on the materials approved in the past or if the Society considers it unnecessary. When the applicant desires omission of confirmatory survey, an application stating the reasons thereof is submitted with the application for approval.

1.6 Approval Tests

1.6.1 Approval Tests 1 The tests required for each fire protection materials specified in 1.3 are carried out in testing laboratories recognized by the Society.


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2 The Society may require additional tests, however, if it considers necessary.

1.7 Notice of Approval

1.7.1 Notice of Approval The Society issues the Certificate of Approval for Fire Protection Material after having approved the material by the general judgment on the basis of the results of examination of the submitted documents and the results of the confirmatory survey of manufacturer for approval and approval tests.

1.7.2 Validity of Certificate of Approval for Fire Protection Material The Certificate of Approval for Fire Protection Material is valid for five years.

1.8 Marking

The approved fire protection materials are identified by a mark showing that they are the materials approved by the Society.

1.9 Quality Assurance

1.9.1 Tests and Inspections at Time of Shipment 1 When the applicant or both of the applicant and the manufacturer, if the applicant is not a manufacturer, is/are the manufacturers assessed and approved in accordance with the Rules for Approval of Manufacturers and Service Suppliers by the Society or has/have a quality control system assessed and approved in accordance with the recognized standard (for example, ISO 9000 series), the quality assurance of products is subject to the following (1) through (3) and tests and inspections at the time of shipment may not be attended by a surveyor of the Society. (1) The manufacturer or applicant is assures the quality of the approved material by conducting the process control

and quality control including various in-plant inspections under its responsibility. (2) The Society may require the results of in-plant tests on the approved materials when it considers necessary. (3) When the constituent materials, process of manufacture, etc. are changed, an immediate notice thereof is given

to the Society. 2 When the applicant or both of the applicant and the manufacturer, if the applicant is not a manufacturer, is/are not the manufacturers assessed and approved in accordance with the Rules for Approval of Manufacturers and Service Suppliers by the Society or does/do not have a quality control system assessed and approved in accordance with the recognized standard, tests and inspections at the time of shipment are carried out in the presence of the Surveyor in accordance with following (1) or (2). However, additional tests and inspections may be required where deemed necessary by the Surveyor. (1) For fire protection materials other than fire retardant coatings, the inspection of results of in-plant tests, the

visual inspection, the dimension measurement and the inspection of the marking are carried out. (2) For fire retardant coatings, the inspections of results of in-plant tests, kinds of materials, the table of chemical

composition and the marking are carried out.

1.10 Periodical Test

1.10.1 Interval of Periodical Test Periodical test is carried out before or on the expiry date of the Certificate of Approval for Fire Protection Material.

1.10.2 Periodical Tests for Approved Materials Other Than Fire Retardant Coatings 1 An application for periodical test (Specimen Form 4-3) accompanied with necessary copies of the records of manufacture and the specifications of the products specified in 1.4.3-1(6) is submitted to the Society (Head Office). 2 The tests specified in 1.3.1 through 1.3.8 are carried out. The tests may, however, be omitted if the Society considers appropriate. 3 After the application for the periodical test and necessary data have been received, the Society’s surveyor carries

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out the confirmatory survey of manufacturer for verifying that the materials are manufactured in accordance with the same process of manufacture employed when the materials were previously approved. The survey may, however, be omitted when the Society considers unnecessary. 4 After the application for the periodical test and necessary data have been received, the tests specified in -2 above are carried out under the direction of the Society (Head Office) and the test report is submitted to the Society (Head Office). The test report is of an original or a duplicate copy issued by a testing laboratory specified in 1.6.1-1.

1.10.3 Periodical Test for Fire Retardant Coatings 1 An application for periodical test (Specimen Form 4-4) accompanied by necessary copies of the records of manufacture and the list of coating system and the table of chemical composition specified in 1.4.3-2(5) and (6) respectively is submitted to the Society (Head Office). 2 The tests specified in 1.3.9 are carried out. The tests may, however, be omitted if the Society considers appropriate. 3 After the application for the periodical test and necessary data have been received, the Society’s surveyor carries out the confirmatory survey of manufacturer for verifying that the materials are manufactured in accordance with the same process of manufacture employed when the materials were previously approved. The survey may, however, be omitted when the Society considers unnecessary. 4 After the application for the periodical test and necessary data have been received, the tests specified in -2 above are carried out under the direction of the Society (Head Office) and the test report is submitted to the Society (Head Office). The test report is of an original or a duplicate copy issued by a testing laboratory specified in 1.6.1-1.

1.10.4 Notice of Renewal 1 The Society issues the Certificate of Approval for Fire Protection Material which is valid for five years from the date of completion of the periodical tests when the Society ascertains continuous compliance with the type approval conditions by the review of the test report of the periodical tests specified in 1.10.2 or 1.10.3. 2 When the periodical test is completed within three months before the expiry date of the existing certificate, the new certificate is valid from the date of completion of the periodical test to a date not exceeding five years after the date of expiry of the existing certificate.

1.11 Confirmatory Test

1.11.1 Confirmatory Test The confirmatory test is conducted when one of the following conditions occurs on an occasion different from the periodical test: (1) In case of doubt on the quality of products, judging from the service records of the approved materials (2) When the Society recognizes the necessity of the test because of the change of the constituent materials, in the

process of manufacture, in the method of application, etc. (3) When the Society considers necessary.


1.12.1 Revocation of Approval The approval may be revoked if one of the following conditions is found relevant : (1) Failure in periodical test or confirmatory test (2) Abandonment of undergoing periodical test or confirmation without any unavoidable reason (3) When the applicant makes an offer or withdrawal (4) When any alteration is made intentionally or by unsatisfactory quality control to the approved condition which

might cause change in the quality of product (5) When an inconsistency produced intentionally or accidentally is found between the actual condition and marking

of the product. (6) When the fees and expenses of the tests are not paid (7) When a condition in which the Society considers that renewal of approval is not appropriate takes place.


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1.13 Test Procedures

1.13.1 Non-Combustibility Test Test procedures of the non-combustibility test are in accordance with the requirements of Part 1, Annex 1 of FTP Code.

1.13.2 Smoke and Toxicity Test Test procedures of the smoke and toxicity test are in accordance with the requirements of Part 2, Annex 1 of FTP Code.

1.13.3 Test for “A” and “B” Class Divisions Test procedures of the test for “A” and “B” class divisions are in accordance with the requirements of Part 3 (except Appendix 2), Annex 1 of FTP Code.

1.13.4 Test for Continuous “B” Class Divisions Test procedures of the test for continuous “B” class divisions are in accordance with the requirements of Part 3 (except Appendix 1), Annex 1 of FTP Code.

1.13.5 Test for Surface Flammability Test procedures of the test for surface flammability are in accordance with the requirements of Part 5, Annex 1 of FTP Code.

1.13.6 Test for Primary Deck Coverings Test procedures the test for primary deck coverings are in accordance with the requirements of Part 6, Annex 1 of FTP Code.

1.13.7 Fire-Restricting Materials for High-Speed Craft The test procedures of the test for fire-restricting materials for high-speed craft are to be in accordance with the requirements of Part 10, Annex 1 of FTP Code.

1.13.8 Fire-Resisting Divisions for High-Speed Craft The test procedures of the test for fire-resisting divisions for high-speed craft are to be in accordance with the requirements of Part 11, Annex 1 of FTP Code.

1.14 Omission of Testing and Approval

1.14.1 Non-Combustible Materials The following materials are considered being non-combustible, and they may be installed without testing and approval. (1) Glass (2) Concrete (3) Ceramic products (4) Natural stone (5) Masonry units (6) Common metals and metal alloys

1.14.2 “A” Class Divisions The following products are considered being equivalent to class “A-0” bulkheads and class “A-0” decks, and they may be installed without testing and approval. (1) Class “A-0” bulkhead : A steel bulkhead with dimensions not less than the minimum dimensions given below,

(a) Thickness of plating : 4 mm (b) Section modulus : 23 cm3

(2) Class “A-0” deck : A steel deck with dimensions not less than the minimum dimensions given below, (a) Thickness of plating : 4 mm (b) Section modulus : 57 cm3

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1.14.3 Primary Deck Coverings Non-combustible materials are considered to comply with the requirements of tests specified in 1.13.6.

1.15 Omission of Tests

1.15.1 Smoke and Toxicity Test The following materials are considered to comply with the requirements of tests specified in 1.13.2 subject to the approval by the Society. (1) Non-combustible materials (2) Fire retardant veneers, Fire retardant surface floorings and primary with both the total heat release ( tQ ) of not

more than 0.2 MJ and the peak heat release rate ( pq ) of not more than 1.0 kW (both values determined in

accordance with the requirements of tests specified in 1.13.5)

1.15.2 Test for Surface Flammability 1 Non-combustible materials are considered to comply with the requirements of tests specified in 1.13.5. 2 Primary deck coverings classified as not readily ignitable in accordance with the provisions specified in 1.13.6 are considered to comply with the requirements of tests specified in 1.13.5 for fire retardant surface floorings.


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Form 4-1

Form 4-2

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Form 4-3

Form 4-4


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Form 4-5

Entry instructions for Specimen Form 4-1 to 4-5

＊1: Entry is made in accordance with the requirements specified in 1.1 through 1.6 which each materials are referred to in Table 4.1-1.

＊2: To be in accordance with 1.4.3-1. ＊3: Name of department/section and extension telephone number are entered. ＊4: To be in accordance with 1.2.9-2. ＊5: To be in accordance with 1.4.3-2. ＊6: To be in accordance with 1.10.2-1 or 1.10.3-1. ＊7: Designed values are entered.

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Table 4.1-1. Entry instructions for Specimen Form 4-1 to 4-5 Name of fire protection material Kinds Applications

Non-combustible materials No entry required No entry required

“A” class divisions A-60，A-30，A-15，A-0 Bulkheads, decks, fire-retardant doors, windows, fire dampers, pipe and duct penetrations or cable penetrations

“B” class divisions B-15, B-0 Bulkheads, decks, fire-retardant doors, linings, ceilings, windows, fire dampers, pipe and duct penetrations or cable penetrations

Continuous “B” class divisions B-15, B-0 Continuous linings or continuous ceilings

Fire retardant base materials No entry required Fire retardant base materials used for ceilings, linings, draft stops or grounds

Fire retardant veneers No entry required

Fire retardant veneers used for both non-combustible base materials and fire retardant base materials, only for non-combustible base materials or only for fire retardant base materials

Fire retardant surface floorings No entry required No entry required Primary deck coverings No entry required No entry required


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Chapter 2 TYPE APPROVAL OF MATERIALS FOR REFRIGERATED CHAMBERS

2.1 General

2.1.1 Scope The requirements in this chapter apply to tests and inspection for the type approval of materials intended to be used for insulating the refrigerated chambers and oil-impervious composition provided for the surface of oil tanks adjacent refrigerated chambers (hereinafter referred to as “oil-impervious covering”) in accordance with the requirements of 5.2.1-1 and 5.2.5 of the Rules for Cargo Refrigerating Installations.


2.2.1 Procedures Application for type approval is to be made to the Society (Head Office) accompanied by 3 copies each of the documents specified in 2.2.4.

2.2.2 Notice of Alterations If there are major alteration in the process of manufacture, material composition or other approved items, a notice on alterations in the approved items is to be submitted to the Society.

2.2.3 Applicant Material manufacturer is, in general, to be the applicant for type approval except where the applicant other than manufacturer has final responsibility for the quality of products.

2.2.4 Documents The documents concerning to the following items are to be submitted to the Society with the application. (1) History and organization of the manufacturer (2) General description of major manufacturing facilities (3) Specifications of products (4) Packaging and marks (labels, etc.) (5) Process of manufacture (6) Physical properties of products assured by the manufacturer (7) Quality control and quality assurance (including standards of manufacturer’s inspection and organization of the

inspection department) (8) Storage method of products (9) Installation procedures on board including precautions for working, if any (10) Service records (11) Other items considered necessary by the Society

2.2.5 Omission of Documents (1) The manufacturers, who have the products already approved according to the requirements of this chapter, may

omit submission of the documents which is a duplicate of those examined at previous type approval if they so indicate.

(2) The process of manufacture, standards of manufacture, material composition and other items considered confidential to the manufacturer may be omitted from being submitted if they are so declared. However, the Society reserves the rights to survey these items at the confirmation survey of manufacturing and quality control procedures if considered necessary.

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2.3.1 Survey The confirmation survey of manufacturing and quality control procedures is to be carried out to verify the manufacturer’s ability of producing the materials with the stable product quality (facility, technology, quality control/quality assurance system, and manufacturer’s inspection system).

2.3.2 Omission of Confirmation Survey The confirmation survey may be omitted if the Society deems it unnecessary as a result of examination of documents submitted.

2.3.3 Survey Items The following items are to be examined. (1) Manufacturer’s inspection system and organization, and claim disposal department (2) Manufacturing and inspection facilities (3) Quality control and quality assurance system

2.4 Approval Test

2.4.1 General (1) The approval tests specified in 2.4.2 or 2.4.3 are to be carried out in the presence of the Society’s surveyor where

the submitted documents are considered acceptable. (2) Applicants are to submit the test plan describing the test place, testing procedure, etc. in advance. (3) It is recommended that the above test plan is submitted with application form letter. (4) Test samples are to be picked out, in general, from the products by the direction of the Society’s surveyor upon

the survey at confirmation survey. (5) Two copies of the test record are to be submitted to the Society. (6) When the test is carried out at a recognized testing organization, it may be accepted that some or all of the tests

are carried out without the presence of the Society’s surveyor.

2.4.2 Insulation Materials (1) The items represented by mark in Table 4.2-1 are to be tested for the insulation materials. However,

materials not given in the table are to be considered in each case. (2) Testing procedure and acceptance criteria

The testing procedure and acceptance criteria are to be in accordance with the requirements of JIS or other recognized standards.


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Table 4.2-1 Approval Test Items of Insulation Materials Main materials Thermal

conductivity

Density Bending

strength

Pressure

test

Water

absorption

Water

content

Combustion

test

Others

Asbestos Ignition loss

Diatomaceous Fibre content

earth

Rock wool Particle content

Glass wool Diameter of fibre

Basic magnesium Sulfuric acid test

carbonate

Calcium Shrinkage

silicate

Foam

polystyrene

pearlite Water repellency

and Shrinkage

Rigid foam

rubber

Rigid foam

urethane

2.4.3 Oil-impervious Covering (1) Tank top covering

The test items and testing procedure given in Table 4.2-2 are to be carried out for the tank top covering. (2) Tank side covering

The tests are to be carried out in accordance with requirements specified in Table 4.2-2. In addition to these tests, the tests given in Table 4.2-3 are to be carried out for the tank side covering.

Table 4.2-2 Approval Test Items and Testing Procedure for Tank Top Covering for Oil Tanks

Test item Test procedures

Odor test The inner surface of an appropriate container is to be coated with the covering and the outer surface is to be warmed up and kept at 65 by hot water, etc. It is to verified whether or not harmful odor

is generated. Bending strength To be in accordance with JIS A 1106

Compression strength To be in accordance with JIS A 1108

Oil absorption test Test piece of tank top covering (30 cm×30 cm) is to be immersed for 24 hours in heavy oil at 65, and measure the increase of weight. 15% or less of weight increasing is acceptable.

Oil tightness test The tank top covering is to be coated on the top of steel container where 20 holes of 6 mm diameter are drilled with 100 mm pitch.0.2 MPa oil pressure is to be applied to the inner surface

and be kept for 24 hours .It is to be verified that no oil permeates through 6 mm holes.

Combustion test To be in accordance with the combustion test in 2.4.2(2)

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Table 4.2-3 Approval Test Items and Testing Procedure for Tank Side Covering

2.5 Certificate of Type Approval

When the Society is satisfied with the results of the examination of the documents submitted, the survey specified in 2.3 and the approval test specified in 2.4, the Society issue the Certificate of Type Approval for Materials for Refrigerated Chambers. The valid term of the Certificate is remained for 4 years from the date of issue.

Sample of the certificate is attached to the end of this chapter for reference.

2.6 Markings

The marking and packaging are to be as shown in the documents attached to the application for the type approval and no changes are to be made without agreement by the Society. The approval number is to be indicated to declare the type approval by the Society.

2.7 Quality Control and Quality Assurance

2.7.1 General Process of manufacture and the quality of the products are to be assured in accordance with the same procedure and system as they have been surveyed and examined by the Society under the manufacturer’s responsibility.

2.7.2 Results of Production Tests The results of production tests are to be available for review whenever requested by the Society.


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2.7.3 Changes on the Approved Items Changes in the process of manufacture, material composition and other approved items including the change of contents in the approved documents are to be notified to the Society for review. The Society informs the results of the review items, etc. to the manufacturer.

2.8 Periodical Examination

2.8.1 Application for Periodical Examination 1 Manufacturer of the approved materials are to be subjected to the periodical examination at an interval of 4 years. 2 Application for periodical examination is to be made to the Society accompanied by the document describing the Society’s approval number, date of issue of the Certificate and items altered from the original approved conditions, if any.

2.8.2 Tests of Periodical Examination At each periodical examination, the survey items specified in 2.3 and the tests considered necessary by the Society, among the test items specified in 2.4 are to be carried out.

2.8.3 Renewal of the Certificate of Type Approval When the results of the periodical examination are considered are considered acceptable to the Society, the Society reissues the Certificate of Type Approval for Materials for Refrigerated Chambers specified 2.5.

2.9 Revocation of Type Approval

2.9.1 Revocation of Type Approval Type approval be revoked if any of the following cases is found relevant. (1) When doubt occurs on the performance of the approved material as a result of the service record. (2) When the manufacturer is not subjected to the periodical examination. (3) When the material failed to pass the periodical examination. (4) When the manufacturer offers to stop manufacturing the material. (5) When the manufacturer requests to withdraw the type approval.

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Chapter 3 APPROVAL OF RAW MATERIALS FOR HULL OF SHIPS OF FIBREGLASS REINFORCED PLASTICS

3.1 Scope

3.1.1 Application This chapter applies to the approval and retention of approval of the raw materials to be used in the following (1) through (3) for FRP boats conforming to the requirements of 4.2.1 of the Rules for the Survey and Construction of Ships of Fibreglass Reinforced Plastics: (1) Fibreglass reinforcements (2) Liquid resins for laminates (3) Core materials for sandwich construction


3.2.1 Application for Approval Manufacturer who intends to obtain approval is to submit the application in duplicate, stating the brand name and type of raw materials (Specimen Form 4-6) accompanied by the reference materials and data, each in duplicate, as shown in 3.2.3 to the Society (Head Office).

3.2.2 Applicant Applicant is, in principle, to be the manufacturer. However, any person who is solely responsible for the product quality may serve as applicant.

3.2.3 Reference Materials and Data to be Attached to the Application for Approval 1 The following reference materials and data are to be attached to the application for approval: (1) Company background and brief description of the factory (2) Summary of main manufacturing facilities (3) Product specification (4) Manufacturing process (5) Product quality control system (including in-house inspection standards and organizational setup of inspection

department) (6) Product quality assurance system (including claim handling procedure) (7) Product storage method (8) Packaging, packing and marking procedures (9) Service records (10) Other documents as deemed necessary by the Society 2 Notwithstanding the preceding requirements, either part or all of the reference materials and data may be omitted in case where any of the following items is pertinent. In this case, note to be made to this extent in the approval application. (1) In case where the manufacturer has a previous record of approval for the materials in the past and there are

duplicated reference materials and data to be attached to the present application. (2) In case where any of the reference materials and data is under corporate secrecy and thus is unable to be

submitted. Provided, however that submission of these reference materials and data may be requested when the Society deems it necessary.


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3.3.1 Confirmation Survey of Manufacturing and Quality Control Procedure Confirmation survey is be carried out to ensure whether the manufacturer has the capability to manufacture the item of product applied for approval in a uniform manner at the product quality equal to or even better than that for which approval tests has been carried out by conducting survey on factory installations, techniques, product quality control system and in-house inspection facilities through the on-site inspection.

3.3.2 Items of Confirmation Survey The following items are to be investigated at factory investigation: (1) Facilities and organizations for in-house inspection and claim handing (2) Factory installations and inspection facilities (3) Establishment of various in-house regulations, work standards, and product quality control system, and the

status of their implementation

3.3.3 Omission of Confirmation Survey In case where the manufacturing is carried out by nearly the same installations that were used for manufacturing the item of product for which approval was given in the past, and share the Society considers that confirmation survey is unnecessary, the confirmation survey may be omitted for such cases.

3.4 Approval Tests

3.4.1 General Approval tests are to be carried out in accordance with the requirements of 4.2 of Rules for the Survey and Construction of Ships of Fibreglass Reinforced Plastics in the presence of the surveyor of the society.

3.4.2 Test items and Test Procedures The test items and test procedures for approval tests are to be in accordance with the requirements in Chapter 4, Guidance for the Survey and Construction of Ships of Fibreglass Reinforced Plastics.


3.5.1 Submission of Approval Test Records On completion of tests, the applicant is to submit the approval test records, in triplicated, with the signature of the surveyor who attended the tests obtained thereon, to the Society (Branch Office).

3.5.2 Issue of Approval Certificate The Society approves the items of material on finding the results of approval tests and confirmation survey to be satisfactory after examining them and issues approval certificates for each brand of products for each manufacturer who has applied for approval.

3.6 Periodical Tests

3.6.1 General The manufacturer of the approved material is to receive the periodical test including factory investigation in the presence of the surveyor of the Society for each manufacturer at intervals not exceeding 12 months.

3.6.2 Application for Periodical Test The manufacturer is to submit application for periodical test (Specimen Form 4-7), in duplicate, to the Society (Branch Office) before the date of periodical test.

3.6.3 Contents of Periodical Tests 1 Periodical test is, in principle, to be carried out at the manufacturing factory. 2 The factory investigation of periodical test is to be carried out correspondingly with the requirements of 3.3.

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3 Test items and test procedures of periodical test are to be in accordance with the requirements of 3.4. However, a part or whole of the test items may be dispensed with considering the result of factory investigation specified in -2 and the data showing actual manufacturing records.

3.6.4 Postponement of Periodical Tests Periodical test is, in principle, to be completed within the validity of the certificate. However, under unavoidable circumstances, the test may be completed with the Society’s approval within three months after expiry of the validity.

3.6.5 Submission of Test Records On successful completion of periodical test, the manufacturer is to submit the test results, in duplicate, with the attending surveyor’s signature on them to the Branch Office of the Society concerned.

3.6.6 Renewal of Validity of Certificate For the approved materials that passed the periodical test, the Society (Branch Office) makes renewal of the validity of the certificate. The validity is, irrespective of the date of completion of the periodical test, to be full one year counting from the next day of expiry of the previous validity.

3.6.7 Control of Periodical Test Dates Periodical test dates are to be controlled by the Society (one of its branches).

3.7 Occasional Tests

In case where either one of the following items is relevant in time other than the periodical test, occasional test is to be carried out: (1) When there is doubt about the product performance from the experience of actual use of the approved material. (2) When tests and inspection are deemed necessary by the Society due to change in the manufacturing process. (3) Other cases than above deemed necessary by the Society.


Approval may be revoked if request is made by the applicant, or in any case of items from (1) to (3) of the requirements of 4.2.3 of Rules for the Survey and Construction of Ships of Fibreglass Reinforced Plastics is relevant.

3.9 Indication

The manufacturer is to affix the approval number to raw materials for hull of ships of fibreglass reinforced plastics in order to clarify that they have been approved by the Society.


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Form 4-6

Part 4 Chapter 3

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Form 4-7


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Chapter 4 APPROVAL OF ANTI-CORROSIVE PAINTS FOR CORROSION CONTROL (CoC)

4.1 Scope

4.1.1 Application The requirements of this chapter apply to the approval of anti-corrosive paints specified in 1.1.21, Part C of the Rules for the Survey and Construction of Steel Ships.


4.2.1 Application for Approval Manufacturer who intends to obtain approval is to submit the application, in duplicate, stating the type and uses of the paints (Specimen Form 4-8) accompanied by the reference materials and data, each in duplicate, as shown in 4.2.2 to the Society (one of its branches).

4.2.2 Reference Materials and Data to be Attached to the Application for Approval The following reference materials and data are to be attached to the application for approval: (1) Company background and brief description of the factory (2) Summary of main manufacturing facilities (3) In-house inspection department, claim handling organization and inspection facilities (4) Reference materials and data relating to the manufacturing process and quality control system:

Blending details of key components (including the content of aluminium), matters relating to mixing and storage procedures

(5) Matters relating to packaging, packing and shipment (6) Instructions for the application of the paint for which brand approval is made :

Surface preparation, required thickness of coat, painting procedure, and matters relating to drying process and multiple coatings

(7) In-house test results and real ship service experience of the paint brand for which approval is made. Approval certificates issued by other authorities, if any

(8) Matters relating to falling ball impact test and explosion test (9) Other reference materials and data as deemed necessary by the Society

4.3 Confirmation Survey of Manufacturing and Quality Control Procedure

4.3.1 Survey The confirmation survey is to be carried out to ensure whether the manufacturer has the capability to manufacture uniform quality of paints continuously for which approval has been applied by conducting survey on the manufacturing capability (factory installations, techniques, product quality control system, and in-house inspection facilities).

4.3.2 Items of Confirmation Survey In the factory investigation, the following items are to be investigated : (1) In-house inspection facilities and claim handling system (2) Manufacturing and inspection facilities (3) Work standards and product quality control system

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4.4 Approval Test

4.4.1 Approval Test Approval tests are to be carried out in the presence of the surveyor of the Society on the test items specified in 4.4.2. However, if the tests are carried out by an authorized organization (public organization) deemed appropriate by the Society, part of the approval tests in the presence of the surveyor of the Society may be omitted.

4.4.2 Types of Test The types of approval tests are to be as specified below. However, in case where these requirements are found impracticable due to special type of paints, separate considerations may be given. (1) Physical properties tests

(a) Cross-cut adhesion test (b) Erichsen test (c) Falling ball impact test (d) Flex cracking test

(2) Corrosion resistance test (a) Salt water immersion test (b) Gasoline immersion test (c) Hot water immersion test (d) Alternate salt water immersion test (e) Alternate salt water/gasoline immersion test (f) Alternate salt water/crude oil immersion test (g) Salt water spray test Notes:

(1) In case when materials other than salt water crude oil and gasoline are scheduled to load in the tank applied CoC, corrosion resistance test for the materials is to be carried out. The test method considered appropriate by the Society is to be applied.

(2) Gasoline immersion test, Salt water/gasoline immersion test and salt water/crude oil immersion test may not be required for the paint used for sea water ballast tanks.

4.4.3 Test Coupons 1 Number of test coupons

Three each test coupons for each test item specified in 4.4.2 are to be prepared. 2 Shape of test coupon (1) Test coupon for physical properties test

To conform to the requirements of 4.4.4. (2) Test coupon for corrosion resistance test

Standard shape of the test coupon is to be as shown in Fig. 4.4-1. On one face of the test coupon, the paint of the brand under approval application, and on the other side thereof, the paint of ordinary brand (one each oil paint, vinyl and others) for comparative assessment (4.4.3-1) are to be coated. Three test coupons coated on both side with the paint of brand under approval application and each one of test coupon coated with ordinary paint may be accepted as an alternative means.

3 Surface treatment, primer paint and coating. The surface treatment and painting are to be carried out in accordance with the instruction submitted under the

provisions 4.2.2(6). The thickness of paint coat is to be of the minimum recommended by the manufacturer.


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Fig. 4.4-1 Test Coupon for Corrosion Resistance Test

4.4.4 Test Details and Acceptance Criteria 1 Physical properties tests

The testing procedures and acceptance criteria are to be as given in Table 4.4-1. 2 Corrosion resistance test (1) Testing procedures

(a) Salt water immersion test The test coupon is to be immersed in a 5% salt water kept at a temperature of 50±5 over a period of 3,000 hours or more. At such times as before immersion, 1,000th hours from the initiation of immersion (taking photographs only), and on completion of immersion, the thickness of paint coat is to be measured and colour photographs are to be taken at each such time.

(b) Gasoline immersion test The test coupon is to be immersed in gasoline for 3,000 hours under room temperature. At such times as before immersion, 1,000th hours from the initiation of immersion (taking photographs only), and on completion of immersion, the thickness of paint coat is to be measured and colour photographs are to be taken at each such time.

(c) Hot water immersion test Fill a container with tap water and heat it to a temperature 80±5 and keep the test coupon immersed in it continuously for 1,000 hours and then take it out and examine the condition of the paint coat. If there is no abnormality, the test coupon is to be examined after being left for 2 hours. The thickness of paint coats before and after immersion are to be measured with colour photographs taken.

(d) Alternate salt water immersion test After immersing in a 3% salt water solution under room temperature for a period of 168 hours (7 days), the test coupon is to be taken out and left in air for 168 hours. Taking this as one cycle, the test coupon is to be subjected to 10 such cycles consecutively. The paint coat thickness is to be measured and colour photographs of the test coupon are to be taken on completion of the 5th cycle and before immersion of the next attempt.

(e) Alternate gasoline/salt water immersion test Two tanks respectively filled with 3% salt water solution and gasoline are to be prepared and the test coupon is to be immersed in either of them for a period of 168 hours (7 days) and then taken out and immersed in the other tank for another 168 hours. Considering this as one cycle, the process is to be repeated for 10 cycles. Colour photographs and paint coat thickness measurements before immersion, on the 5th cycle, and on completion of the test are to be taken.

(f) Alternate salt water/crude oil immersion test Tests similar to (e) above are to be carried out with 3% salt water solution and crude oil. Colour photographs and paint coat thickness measurements before immersion, on the 5th cycle (only photograph is to be taken), and on completion of the test are to be taken.

(g) Salt water spray test Continuous test with salt water spray is to be carried out for a period of 3,000 hours or more. Colour

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photographs and paint coat thickness measurements before immersion, on the 1,000th hour, and on completion of the test are to be taken.

(2) Acceptance criteria The acceptance criteria for the corrosion resistance tests are to be as given in Table 4.4-2.

(3) During execution of the corrosion resistance tests, the surveyor of the Society may attend and make investigation necessary for verification.

3 Real ship tests (1) The paints, which have passed the paint coat performance tests successfully, are to be subjected to real ship tests.

For the real ship and specific painting areas, the manufacturer may give instructions after obtaining approval of the Society. The painting procedures and surface treatment are to be as instructed by the document under the provision 4.2.2(6), and after application of the paints, visual inspection of paint coat, taking colour photographs are to be carried out in the presence of the surveyor of the Society. In ships having a post-painting period of two years, visual inspection, and taking of colour photographs are to be carried out at time of drydocking in the presence of the surveyor of the Society. Standard blistered or peeled off area of the paint coat is to be 1% or less of the total painted area.

(2) If the paint has been applied to a ship which has already been put into service for 2 years or more, this paint may be regarded is test sample in (1).

Table 4.4-1 Physical Properties Test

Testing procedure Acceptance criteria (1) Cross-cut adhesion test

The test coupon is to be of a mild steel plate of a suitable size for testing. With a sharp knife point the paint coat on the test coupon is to be pierced right down to the steel surface in both the horizontal and vertical directions at 25 places at 2 mm pitch. Stick adhesive tape on the squared-off area encompassed by the 5th vertical and the horizontal line and pull off the tape quickly to judge with the unaided eyes how much of the coat is left on the test coupon.

If the mean of 3 test coupons is 20/25 or more, the test is to be considered successful.

(2) Erichsen test A mild steel test coupon of approximately 200 mm×100 mm×0.8 mm

coated on a single side is to be subjected to the Erichsen test with a punch diameter of 20 mm, pushing speed 0.1 mm/sec., and pushing distance 6 mm.

For a successful test, peeling-off area of at least two out of three test coupons are to be within 1.0 mm2.

(3) Falling ball impact test A mild steel test coupon of approximately 200 mm×100 mm×4 mm

coated on one side is to be fixed on a steel base with the painted surface facing upwards and subjected to falling ball impact test with an weight of 300 g dropped thrice from a height of 2.4 m. Thereafter the condition of the paint surface is to be checked after leaving the test coupon at room temperature for a period of one hour.

If cracks and peelings occur in two out of three test coupons and more, the test is not to be approved.

(4) Flex cracking test A 150 mm×50 mm×0.3 mm tinned plate is to be painted on one side and

flexed through 180° at room temperature keeping the coated side as the outer side (flexing diameter 10 mm, flexing time approximately 1 second).

If cracks and peelings occur in two out of three test coupons and more, the test is not to be approved.

Table 4.4-2 Acceptance Criteria

Class of defects Size of crack or blister Coefficient of defect No. if defects×coefficient of defect

(mm) Total number of defects of three test coupons

A (fine) 1 or below 3 B (small) 1~2 5 10 or below C (medium) 2~3 7 D (large) 4 or more 10


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4.5.1 Notification of Acceptance of Paint Coat Performance Tests On completion of the paint coat performance tests, the manufacturer is to submit an assorted test record, in triplicate, to the Society (Branch Office). If the results are found to be satisfactory, the Society issues written notice of provisional approval to the manufacturer.

4.5.2 Approval Notice In case where the results of real ship tests are found to be satisfactory, an approval notice is issued by the Society to the manufacturer.

4.6 Verification Tests

4.6.1 Verification Test Verification tests may be required to be carried out if the performance of the approved paints in actual use appears doubtful or deemed necessary by the Society.

4.7 Marking

4.7.1 Marking For formally approved paints, at least the following items are to be clearly marked on the paint container labels or other suitable places. (1) Brand name of paint (2) The Society’s approval seal, NK CoC notation and approval number (3) Place of application (4) Year and month of manufacture, and manufacturing number (5) Name of manufacturer


4.8.1 Approval may be revoked if any of the following items is pertinent : (1) If the results of the occasional investigation proves to be unsatisfactory (2) When application for withdrawal is requested by the manufacturer

4.9 Designated Organizations

4.9.1 The organizations designated by the Society under the provisions of 4.4.1 are as follows:

Japan Paint Industry Association Head office East Bldg., 1-5-26 Moto Akasaka, Minato-ku, Tokyo Phone : (03)3478-3451

Eastern Branch Inspection Office 428 Miyamae, Fujisawa City, Kanagawa Prefecture Phone : (0466)27-1121

Western Branch Inspection Place 2-3 Narita-cho, Neyagawa City, Osaka Prefecture Phone : (0720)31-1021

Part 4 Chapter 4

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Form 4-8


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Chapter 5 APPROVAL OF MANUFACTURING PROCESS OF NON-METALLIC BEARING MATERIAL FOR RUDDERS

5.1 General

5.1.1 Scope This chapter applies to the testing and inspection for the approval of manufacturing process of non-metallic bearing material for rudders specified in the requirements of 3.9, Part C of the Rules for the Survey and Construction of Steel Ships.


5.2.1 Approval Application Form Manufacturers wishing to obtain the approval of manufacturing process of non-metallic bearing material for rudders are to submit a single copy of the Approval Application Form (Specimen Form 4-9).

5.2.2 Data to be submitted 1 Three copies each of the drawings and documents given as follows to be submitted together with the Approval Application Form specified in 5.2.1. (1) Test plan for approval (2) Data on outline of manufacturing plant (location, history, organization diagram, number of employees, main

products, actual manufacturing results of the material concerned) (3) Data on main manufacturing facilities, inspection and testing facilities (4) Data on manufacturing procedures and inspection and testing procedures of the bearing material (5) Data on the quality system (a systematic list of codes and standards, control of the measuring instruments and a

procedure of non-conformity and corrective action) (6) Data on specifications of the bearing material (7) Data on storage, packaging and making method of the bearing material (8) Other documents deemed necessary by the Society. 2 Notwithstanding the requirements in preceding -1, in case where the manufacturer have already acquired the Approval of Manufacturing Process of other type of bearing materials in such a case, if the previous approved documents are duplicated to the above required ones, a part or the whole of the documents may be exempted from submission except for the test plan for approval.

5.3 Field Assessment of the Manufacturer

5.3.1 Aim of Field Assessment of the Manufacturer Aim of Field Assessment of the Manufacturer is to verify, by means of the data specified in 5.2.2, whether the manufacturer has the capability (facilities, manufacturing techniques, product quality, etc) to manufacture the bearing material with a stable quality.

5.3.2 Omission of Field Assessment of the Manufacturer In case where the manufacturer is carried out by nearly the same installations that were used for manufacturing the item of product for which approval was given in the past, and the Society considers that field assessment of the manufacturer is unnecessary, the field assessment of the manufacturer may be omitted for such cases.

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5.4 Approval Test

5.4.1 General For the product being required approval test, approval tests are to be carried out in accordance with the test plan approved by the Society.

5.4.2 Attendance of the Society’s Surveyor for Test As a rule, the Society’s Surveyor is to be present when the test samples for the approval test are being identified and when the approval test is being carried out.

5.4.3 Specifications of Approval Test Items, processes and evaluation criteria of the approval test are specified in Table 5.1.

Table 5.1

Items of investigation

Contents Test procedure

Hardness* Between 60 and 70 Shore D Maximum surface pressure

Shore hardness test (JIS Z 2246)

Swelling To ascertaining if unreasonable swelling caused by absorbing water is occurred

Water absorption (JIS K 6911)

Thermal expansion To ascertaining if unreasonable thermal expansion is occurred

Heat shrinkage Percentage (JIS K 6911)

Note: ＊ A hardness test may be carried out with the method as deemed appropriate by the Society at the temperature of 23

and the humidity of 50%.

5.4.4 Submission of Test Records After completion of the approval test, the manufacturer is to produce records of approval test, and is to submit the three copies to the Society upon receiving confirmation by the Society’s Surveyor.

5.5 Approval

5.5.1 Notification of Approval The Society, when it considers that the result of field Assessment and approval test are appropriate, is to approve the manufacturing process of bearing materials applied for, give notice to the manufacturer and inform the branch office.

5.5.2 Valid Term A valid term of the approval certificate is 5 years from the date of the initial or renewal approval. In case where the renewal assessment is carried out within 3 months before the expiry date, a valid term of the certificate is 5 years from the expiry date.

5.5.3 Renewal of Approval Field Assessment of the Manufacturer and Approval Test at renewal of approval are to be carried out in accordance with the requirements of 5.3 and 5.4. However, a part or whole of the test items may be dispensed with considering the data showing actual manufacturing records.


5.6.1 General Bearing materials which conform to the requirements of this chapter may be dealt with as “the type as deemed


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appropriate by the Society” in the requirements in Table C3.2, Part C of the Rules, unless the Society gives additional instructions.

5.6.2 Indication of the Approval Number The manufacturer is to affix the approval number to non-metallic bearing material for rudders in order to clarify that they have been approved by the Society.

Form 4-9

Part 6 Chapter 1

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Part 6 MACHINERY

Chapter 1 APPROVAL OF STANDARDIZED DESIGN FOR MACHINERY AND EQUIPMENT

1.1 General

1.1.1 Scope The requirements of this chapter deal with the approval of the drawings and documents which are submitted in advance to the Society as the standardized design designating the construction, dimensions, materials, specifications, etc. on machinery and equipment required to obtain approval by submitting drawings to the Society in accordance with the requirements of 2.1.2, Part B of the Rules for the Survey and Construction of Steel Ships and 2.3.1-2 of the Rules for Cargo Handling Appliances and 2.1.1 of the Rules for Cargo Refrigerating Installations.

1.2 Application

1.2.1 Application Form The manufacturer, who intends to obtain the approval of standardized design, is to submit an application (Specimen Form 6-1(1)) filled in with necessary data and information to the Society (Head Office).

1.2.2 Drawings and Documents In accordance with the requirements of the rules applicable to the machinery and equipment, drawings and documents, in triplicate, are to be submitted together with the application form specified in 1.2.1.

1.3 Approval

1.3.1 Notification and Announcement of Approval 1 The Society, when satisfied upon examination that the drawings and documents fulfill the requirement concerned, will agree on handling these drawings and documents as the stardardized design. Then one copy each of the drawings and documents will be returned to the applicant with approval stamp of the Society, approval date, approval number and term of validity indicated on them. 2 The Society will make announcement the approval of standardized design per the list published annually.

1.3.2 Term of Validity The term of validity of the approval of standardized design will be five years from the date of approval.

1.3.3 Renewal of Approval 1 The manufacturer, who intends to have a continuation of the approval of standardized design already expired or to make partial modification on the design, is to submit an application in accordance with the requirements of 1.2 newly. 2 In case where approval is given for a design with partial modification, expiration date will not be renewed in principle.

1.3.4 Revocation of Approval In case where either of the following (1) or (2) applies, the Society will revoke the approval of standardized design, and give a notice to the manufacturer. (1) In association with the implementation or revision of international conventions, laws and regulations, the

machinery and equipment for which the standardized design were approved do not deserve the approval any longer.


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(2) Serious shortcomings are found in the machinery and equipment manufactured according to the approved standardized design after being installed in ships.

1.4 Handling after Approval

1.4.1 Allocation of Machinery and Equipment to Ships In case where the machinery and equipment for which the standardized design have been approved are allocated to NK-classed ships, the application (Specimen Form 6-1(2)) for manufacturing of the machinery and equipment is to be submitted to the Society (Head Office), in triplicate, in place of the drawings and documents required by the rules.

Form 6-1(1)

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Form 6-1(2)


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Chapter 2 TYPE APPROVAL OF USE OF MACHINERY AND EQUIPMENT

2.1 General

2.1.1 Scope The requirements of this chapter deal with the tests and inspection relating to the approval of the machinery and equipment listed for which approval of the Society is to be obtained in advance before they are used in ships as required by the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”). (1) Power transmission systems other than gearings (5.2.4-1, Part D of the Rules) (2) Kind 1 propeller shafts with rubber sleeve (6.2.7-1, Part D of the Rules) (3) Kind 1 propeller shafts with synthetic resin sleeve (6.2.7-1, Part D of the Rules) (4) Propeller shafts made of corrosion resistant materials (6.2.7-1, Part D of the Rules) (5) Stern tube bearings (6.2.10-1(3), Part D of the Rules) (6) Stern tube sealing devices (6.2.10-2, Part D of the Rules) (7) Pipes of special materials (12.1.6-1, Part D of the Rules) (8) Special valves and pipes fittings (12.3.2, Part D of the Rules) (9) Systems and equipment for ships carrying liquefied gases in bulk (Part N of the Rules and Part N of the

Guidance for the Survey and Construction of Steel Ships) (10) Air pipe automatic closing devices (13.6.2-2, Part D of the Rules) (11) Flexible hose assemblies (12.3.4-2, Part D of the Rules) (12) Others which are considered necessary by the Society

2.2 Application

2.2.1 Application Form The manufacturer, who intends to obtain the type approval of machinery and equipment, is to submit an application (Specimen Form 6-2) filled in with necessary data and information to the Society (Head Office).

2.2.2 Documents 1 The drawings and data required by the relevant provisions of the Rules applicable to the machinery and equipment and the data listed (1) through (7) below, each in triplicate, are to be submitted together with the application form specified in 2.2.1. (1) Technical information on the machinery and equipment (2) Introduction of the manufacturing plant (3) Information on the manufacture and quality control of the machinery and equipment (Work procedure manual,

etc.) (4) Records of manufacture and delivery of the machinery and equipment (5) Other data considered necessary by the Society (6) Approval test plan (the place of test and scheduled date of test are to be entered) (7) Test records (when preliminary test is carried out) 2 The items of data to be submitted under the requirements of the preceding -1 may be modified depending on the construction of machinery and equipment.


2.3.1 Approval of Test Plan The Society will examine the approval test plan submitted under the requirements of 2.2.2-1(6), approve it when considered acceptable, and return it back to the applicant. In this case, when the Society so considers, part of the approval test items may be omitted.

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2.3.2 Confirmation of Manufacturing and Quality Control Procedure On the basis of the data submitted in accordance with 2.2.2-1, the Society may make investigation of the condition of manufacturing plant when deemed necessary.

2.4 Approval Tests

2.4.1 General The tests specified in the relevant provisions of the Rules and their Guidance relating to the machinery and equipment, and additionally, the detailed tests peculiar to the machinery and equipment as prescribed in 2.4.2 are to be carried out.

2.4.2 Details of Tests 1 In the approval tests plan prescribed in 2.2.2-1(6), the test items specified in -2 to -10 as applicable to the machinery and equipment concerned and additionally those deemed necessary by the Society are to be included. 2 In the approval tests of power transmission systems other than gearings, the following items (1) through (5) are to be included. For systems intended to control a deflection as well as a torsion, the tests in (1) through (5) are to be carried out under the condition of imposing the maximum allowable deflection. (1) Test to confirm the allowable mean torque (2) Test to confirm the maximum allowable transient torque (3) Test to confirm the allowable alternating torque (imposing the mean torque) (4) Test to confirm the value of torsional rigidity (5) Other test as deemed necessary by the Society due to the own construction 3 In the approval tests of Kind 1 propeller shafts with rubber sleeve, the following items (1) and (2) are to be included : (1) The following physical tests by the method specified in JIS K 6251, 6252, 6253, 6254, 6256, 6257 and 6258.

In these tests, test specimens are to be vulcanized under the condition shown in “Work Procedure Manual” for the maximum diameter of propeller shaft for which an approval will be given. (a) Tensile test (including elongation test) (b) Hardness test (c) Tear test (d) Test for static modulus of elasticity (e) Aging tests relating to items (a) to (d) (f) Dipping test (g) Adhesion test (bonded parts between rubber, ebonite, shaft and sleeve)

(2) Peeling test by the method indicated in JIS K 6301 In this case, the test shaft to be of a model shaft with the maximum diameter worked up in accordance with the “Work Procedure Manual”.

(3) Following items are to be included in the “Work Procedure Manual” referred to in the preceding items (1) and (2) and 2.2.2-1(3) : (a) The shape of the copper alloy sleeve on which rubber sleeve is bound. (b) Work details including the materials used, construction, dimensions, vulcanizing conditions (temperature,

pressure and time interval) of the portion of rubber sleeve. (c) The procedure of permanent marking on the product (serial No., date of manufacture, name of company

who carried out the work, the Society’s approval No., material of the mark tag, size, etc.) 4 For the approval tests of Kind 1 propeller shafts with synthetic resin sleeve, the following items (1) to (4) are to be included : (1) Watertightness verification test with the test shaft worked up in accordance with the “Work Procedure Manual”

This test is to be carried out as the endurance test of the watertightness at the portion between synthetic resin sleeve and copper alloy sleeve under repeated twisting and bending loads. In this case, the construction drawing of the test shaft and the drawing of the test rig are to be indicated in the approval test plan.

(2) Adhesion test correspondingly in accordance with JIS K 6256 (adhesion between the bonded areas of synthetic resin, shaft and sleeve)


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(3) Water absorption rate test at the portion of synthetic resins correspondingly in accordance with JIS K 7209 (4) Falling ball impact test at the portion of synthetic resins correspondingly in accordance with JIS K 7211 (5) Following items are to be included in the “Work Procedure Manual” referred to the preceding (1) and

2.2.2-1(3) : (a) Environmental conditions involved in the work (b) Environment control system relating to temperature, humidity, sanitation, etc. (c) Work procedure of the shape at the portion of the copper alloy sleeve where synthetic resin sleeve is bound (d) Work details including the materials, construction, dimensions, etc. at the portion of synthetic resin sleeve (e) The procedure of permanent marking on the product (serial No., date of manufacture, name of company

who carried out the work, the Society’s approval No., material of the mark tag, size, etc.) 5 In the approval tests of propeller shafts made of corrosion resistant materials such as stainless steel, non-ferrous materials, etc. the items specified below are to be included in addition to those required for the materials themselves by the requirements of Part K of the Rules. (1) Bending and torsional fatigue tests in sea water (2) Test to confirm residual stresses (3) Test to confirm the pitting potential 6 In the approval tests plan of stern tube bearings, the following items are to be included : (1) Drawing of the test rig (2) Drawing of the test product (specified the materials, dimensions, etc.) (3) Condition of tests (lubrication system, shaft speed, bearing load, hydraulic pressure, test time, etc.) (4) Content of tests

(a) Confirmation tests for the characteristics of materials i) In the case of vulcanized rubber, the following tests specified in JIS K 6251, 6252, 6253, 6256, 6257,

6258 and 6262 : 1) Tensile test 2) Hardness test 3) Tension permanent set test 4) Adhesion test 5) Test for adhesion to metals (except those not to be adhered to metals) 6) Tear test 7) Compression permanent test 8) Dipping test (in the case of a waterlubricated system, tests are to be carried out using sea water)

ii) In the case of materials other than those specified above in i), tests according to pertinent national standards or other equivalent standards concerning the contents of i) according to the materials.

(b) Abrasion test (c) Seizure critical load test (d) Running test (in this case, confirm that the bearing pressures during the tests are to be verified are not less

than 0.8 MPa for an oil lubricated system, and are not less than 0.2 MPa for a water lubricated system respectively.)

7 In the approval tests of stern tube sealing devices, the following items are to be included : (1) Drawings of the test rig (2) Drawings of the test product specifying the construction, materials, dimensions, etc. (3) Plans of test conditions specifying the lubrication system, shaft speed range, surface pressure of the bearing,

hydraulic pressure, test hours, etc. 8 In the approval tests of pipes of special materials, the following items are to be included according to their applications and kinds of materials as deemed necessary by the Society : (1) Tests specified in JIS K 6330 and K 6349 (2) Flame-resistant test

This test applies to piping system containing fuel oil, lubricating oil, hydraulic oil and sea water where leakage or failure could result in fire or flooding in the machinery space. The testing procedures are to be as follows : The test pipe at the design pressure (in the case of less than 0.5 MPa, 0.5 MPa is to be taken) and the design temperature (in the case of less than 80, 80 is to be taken) with fluid flowing through is to be exposed to a

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flame and held at a temperature of 800 on the surface for a period of 30 minutes. Following the fire test, pressure test is to be carried out at a pressure twice the design pressure (in the case of less than 1 MPa, 1 MPa is to be taken) whereby it is to be verified if the test pipe free from abnormality.

(3) For rubber hoses used for the contact freezer, the tests specified in the following(a) and (b) : (a) Pressure test at a pressure twice the design pressure or 2 MPa, whichever is the greater (b) Rupture test at a pressure of 8 MPa or more

9 In the approval tests of special valves and pipe fittings (except mechanical joints specified in Chapter 9 and flexible hose assemblies specified in -11), the following items (1) through (7) as deemed necessary by the Society are to be included according to the application and type: (1) Pressure test (2) Vibration test (3) Impact pressure test (for those used in piping system subjected impact pressure) (4) Low temperature test (for those used at low temperature) (5) Flame-resistant test (where necessary) (6) Function test (7) Other tests as deemed necessary by the Society 10 Air pipe automatic closing devices are to be designed and tested in accordance with (1) and (2) respectively. (1) Materials and Construction

(a) Materials i) Casings of air pipe closing devices are to be of approved metallic materials adequately protected

against corrosion. ii) For galvanised steel air pipe heads, the zinc coating is to be applied by the hot dip coating and the

thickness is to be 70 to 100 µ m.

iii) For areas directly subjected to ballast water impact when the tank is being pressed up (for example the inner chamber area above the air pipe, plus an overlap of 10 o or more either side), an additional harder coating is to be applied. This is to be an aluminium bearing epoxy or other equivalent coating, applied over the zinc.

vi) Closures and seats made of non-metallic materials are to be compatible with the media intended to be carried in the tank and seawater and suitable for operating at ambient temperatures between -25 and 85.

(b) Construction i) Air pipe automatic closing devices are to be so designed that they will withstand both ambient and

working conditions, and be suitable for use at inclinations up to and including ± 40 degrees. ii) Air pipe automatic closing devices are to be constructed to allow inspection of the closure and the

inside of the casing as well as changing the seals. iii) Efficient ball or float seating arrangements are to be provided for the closures. Bars, cage or other

devices are to be provided to prevent the ball or float from contacting the inner chamber in its normal state and made in such a way that the ball or float is not damaged when subjected to water impact due to a tank being overfilled.

iv) Air pipe automatic closing devices are to be self-draining. v) The clear area through an air pipe closing device in the open position is to be at least equal to the area

of the inlet. vi) An automatic closing device is to :

1) Prevent the free entry of water into the tanks, 2) Allow the passage of air or liquid to prevent excessive pressure or vacuum coming on the tank.

vii) In the case of air pipe closing devices of the float type, suitable guides are to be provided to ensure unobstructed operation under all working conditions of heel and trim.

viii) The maximum allowable tolerances for wall thickness of floats are not to exceed ± 10% of thickness. ix) The inner and the outer chambers of an automatic air pipe head is to be of a minimum thickness of 6

mm.


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(2) Testing (a) Tightness test during immerging/emerging in water

An automatic closing device is to be subjected to a series of tightness tests involving not less than two(2) immersion cycles under each of the following conditions : i) The automatic closing device is to be submerged slightly below the water surface at a velocity of

approximately 4 m/min and then returned to the original position immediately. The quantity of leakage is to be recorded.

ii) The automatic closing device is to be submerged to a point slightly below the surface of the water. The submerging velocity is to be approximately 8 m/min and the air pipe vent head is to remain submerged for not less than 5 minutes. The quantity of leakage is to be recorded.

iii) Each of the above tightness tests is to be carried out in the normal position as well as at an inclinations of 40 degrees.

The maximum allowable leakage per cycle is not to exceed 2 ml/mm of nominal diameter of inlet pipe during any individual test.

(b) Flow characteristic test The flow characteristics of the air pipe closing device are to be determined. Measuring of the pressure drop versus rate of volume flow is to be carried out using water and with any intended flame or insect screens in place.

(c) Testing of non-metallic floats Impact and compression loading tests are to be carried out on the floats before and after pre-conditioning as Table 6.2. i) Impact test

The test may be conducted on a pendulum type testing machine. The floats are to be subjected to 5 impacts of 2.5 Nm each and are not to suffer permanent deformation, cracking or surface deterioration at this impact loading. Subsequently the floats are to be subjected to 5 impacts of 25 Nm each. At this impact energy level some localised surface damage at the impact point may occur. No permanent deformation or cracking of the floats is to appear.

ii) Compression loading test Compression tests are to be conducted with the floats mounted on a supporting ring of a diameter and bearing area corresponding to those of the float seating with which the float is intended to be used. For ball type float, loads are to be applied through a concave cap of the same internal radius as the test float and bearing on an area of the same diameter as the seating. For disc type float, loads are to be applied through a disc of equal diameter as the float. A load of 3.43 kN is to be applied over one minute and maintained for 60 minutes. The deflection is to be measured at intervals of 10 minutes after attachment of the full load. The record of deflection against time is to show no continuing increase in deflection and, after release of the load, there are to be no permanent deflection.

(d) Testing of metallic floats Tests are to be conducted in accordance with (c)i) above. The tests are to be carried out at room temperature and in the dry condition.

11 Flexible hose assemblies are to be approved in accordance with the following tests. (1) For metallic flexible hose assemblies, the following tests correspondingly in accordance with ISO 10380 are to

be included. (a) Pressure test (b) Burst test (c) Fatigue test (d) Bend test (e) Leakage test (f) Other tests as deemed necessary by the Society

(2) For non-metallic flexible hose assemblies, the following tests are to be included. (a) Pressure test and burst test correspondingly in accordance with ISO 1402 (The minimum burst pressure is

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to be not less than four times the design pressure.) (b) Hydraulic impulse test (Correspondingly in accordance with ISO 6802 where with flexing during operation

or ISO 6803 where without flexing during operation) (c) Fire resistance test correspondingly in accordance with ISO 15540 and 15541 (for those used in flammable

oil and sea water pipes) (d) Other tests as deemed necessary by the Society

Table 6.2 Test condition of non-metallic floats

Test condition Test temperature

-25 20 85 Dry + + + After immerging in water ＊ + + + After immerging in fuel oil ＊ - + -

Notes: + : Applicable - : Not applicable ＊ : Immerging in water and fuel oil is to be for at least 48 hours

2.4.3 Witness to Tests When sampling the test products and when the approval test is carried out, they are, in principle, to be carried out in the presence of the Society’s surveyor.

2.4.4 Test Records 1 The manufacturer is to prepare records of the approval test after completion of the test, to obtain verification by the Society’s attending surveyor and to submit them, in triplicate, to the Society. 2 In the test records referred to in -1 above, the data relating to the quality control effected during the manufacturing process of the test product are to be attached thereto.

2.5 Approval

2.5.1 Notification and Announcement of Approval 1 The Society, when satisfied upon examination of the submitted documents as required per 2.2 to 2.4 and the attending surveyor’s report, will issue a certificate of approval specifying the approval number, approval date, items of approval and approval conditions, put approval stamps on the documents as deemed necessary by the Society out of those submitted in accordance with 2.2.2 and 2.4.4, and return them back to the applicant. 2 As one of the approval conditions specified in the preceding -1, the Society may request to prove the performance of the machinery and equipment by limiting tentatively its use to a ship as a test case. 3 The Society will make announcement the approval of the machinery and equipment per the list published annually.

2.5.2 Term of Validity The term of validity of the type approval of machinery and equipment will be five years from the date of approval.

2.5.3 Renewal of Approval 1 The manufacturer, who intends to have a continuation of the approval already expired or to make partial technical modifications of the machinery and equipment, is to submit an application in accordance with the requirements of 2.2 newly. In this case, the data required per 2.2.2 may be limited to the portion subjected to modification only. 2 Where approval is given for the partial modifications in the contents of approval, expiration date will not be renewed, in principle.


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2.5.4 Revocation of Approval In case where either of the following (1) to (3) applies, the Society will revoke the type approval of machinery and equipment, and give notice to the manufacturer. (1) In association with the implementation or revision of international conventions, laws, and regulations, the

machinery and equipment for which the approval was granted do not deserve the approval any longer. (2) When serious shortcomings are found in structure or quality of the machinery and equipment already approved

after being installed ships. (3) When an applications for revocation is made by the manufacturer.


2.6.1 General 1 The test and inspection on the individual product of the type-approved machinery and equipment may be limited to those specified in the approval certificate mentioned in 2.5.1-1 notwithstanding the relevant requirements of the Rules and their Guidance.


Flexible hose assemblies approved by the Society in accordance with 2.4.2-11 are to be marked with the followings.

(a) Manufacturer’s name or trademark (b) Date of manufacture (c) Type number (d) Nominal diameter (e) Pressure rating (f) Temperature rating

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Form 6-2


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Chapter 3 APPROVAL OF COEFFICIENT FOR DISCHARGE OF SAFETY VALVES, ETC.

3.1 General

3.1.1 Scope The requirements of this chapter apply to tests and inspections related to the approval shown below. (1) The approval of coefficient K in the calculation formula of the discharge capacity of safety valves of boilers

(excluding the low-lift safety valves, hereinafter the same in this chapter), based on 9.9.3-5(1), Part D of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”).

(2) The approval of the coefficient K in the calculation formula of the discharge capacity of pressure relief valves of the cargo containment system, process pressure vessels, cargo piping and process piping, based on 8.2.5, Part N of the Rules and Chapter 6, Annex 1, Part N of the Guidance for the Survey and Construction of Steel Ships.

3.2 Application

3.2.1 Application Form The manufacturer, who intends to obtain the approval of coefficient for discharge of safety valves of boilers, or pressure relief valves of the cargo containment system, process pressure vessels, cargo piping and process piping for ships carrying liquefied gas in bulk (hereinafter referred to as “safety valves, etc.”), is to submit an application (Specimen Form 6-3) filled with necessary data and information to the Society (Head Office).

3.2.2 Documents The sectional assembly drawing of the safety valves, etc. and the plan for the tests, each in triplicate, are to be submitted to the Society together with the application form specified in 3.2.1 above.

3.3 Approval Tests

3.3.1 Test Procedures The approval tests are to be conducted on the basis of the procedures for measuring coefficient of discharge specified in JIS B 8225 or those considered to be equivalent thereto in the presence of the surveyor.

3.3.2 Test Records The manufacturer is to submit the test records, in triplicate, after completion of the test to the Society (Head Office).

3.4 Approval

3.4.1 Announcement of Approval The Society, when satisfied upon examination of the drawings and test records submitted in accordance with 3.2.2 and 3.3.2, will issue a certificate of approval specifying the approved K value, put approval stamps on the drawings and test records and return one set of them back to the applicant.

3.4.2 Term of Validity The term of validity of the approval will be five years from the date of the approval.

3.4.3 Renewal of Approval The manufacturer, who intends to have a continuation of the approval which will expire, is to submit an application form in accordance with 3.2.1.

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3.4.4 Modification of Approval Conditions The manufacturer, who intends to make partial technical modifications which will affect the function of discharge on a valve already approved, is to submit an application for modifications in accordance with 3.2. In this case, the Society may require to conduct the tests specified in 3.3 again, when deemed necessary judging from the result of examination of the modification.

3.4.5 Revocation of Approval In case where either of the following (1) to (3) applies, the Society will revoke the approval and give notice to the manufacturer. (1) Where the tests specified in 3.4.4 is not conducted without any reasonable cause. (2) Where an applicant for revocation is made by the manufacturer or the validity of approval is overdue without an

application for renewal. (3) Where the Society considers that the continuation of the approval is in appropriate.


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Form 6-3

Part 6 Chapter 5

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Chapter 5 APPROVAL OF MANUFACTURING BOILERS AND GROUP 1 PRESSURE VESSELS

5.1 General

5.1.1 Scope The requirements of this chapter apply to the tests and inspection concerning to the approval manufacturing boilers or Group 1 pressure vessels for the first time to be installed in ships classed with the Society, in accordance with the requirements of 11.2.1-3, Part D of the Rules for the Survey and Construction of Steel Ships.

5.2 Approval

5.2.1 Approval The manufacturer intending to obtain the approval of the manufacturing boilers or Group 1 pressure vessels is to submit the following documents to the Society: (1) History and introduction of the company (2) General description of major manufacturing facilities (3) Production records of welded structures (4) Chart of organization of manufacturing control system (5) Flow chart of the manufacturing process and code on inspection for the products to be surveyed by the Society

5.2.2 Confirmation of Manufacturing and Quality Control Procedures For the approval of manufacturing boilers and Group 1 pressure vessels, the confirmantion survey is to be carried out on the following items: (1) Manufacturing facilities and inspection facilities

(a) The manufacturing facilities and technical performance to be sufficient for manufacturing the products. The welding facilities are free from the effects of rain and wind and the heat treatment facilities are to have appropriate performance.

(b) Sufficient testing and inspection facilities, such as tensile testing machines, impact testing machines, hardness testers, optical metallurgical microscopes, radiographic testing equipment and magnetic particle flaw detection equipment, are to be provided.

(2) Manufacturing control standards and their detail procedures and code on inspection in effect at the manufacturing plant are to be established.

(3) In case where parts of the above-mentioned manufacturing, testing or inspection work is sublet to sub-contracting plants, the plants are to be subjected to the confirmation survey specified in this 5.2.2.

5.3 Certificate

Where the results of the survey are considered appropriate for manufacturing the products, the Society will issue a certificate for approval of manufacturing the products.

5.4 Validity of Approval

5.4.1 Validity of Approval 1 The valid term of approval in the preceding 5.3 will be five years. 2 In case where renewal of validity is intended, an application stating changes in the manufacturing procedure, etc., if any, is to be submitted to the Society (Survey Office) together with the existing certificate.


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5.5.1 Revocation of Approval Where either of the following (1) or (2) is relevant, the Society may revoke the approval with a notice given to the applicant. (1) In case where the validity of approval is overdue and no application for the renewal of the approval is submitted. (2) In case where doubts arose in the service records of products manufactured by the approved manufacturing

process.

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Chapter 6 APPROVAL OF USE OF PLASTIC PIPES

6.1 General

6.1.1 Scope The requirements of this chapter apply to testing and inspection for approval of use of plastic pipes on ships in accordance with the requirements of 12.1.6, Part D of the Rules for the Survey and Construction of Steel Ships.

6.1.2 Terminology (1) “Plastic” means both thermoplastic and thermosetting plastic materials with or without reinforcement, such as

PVC and fibre reinforced plastics - FRP. (2) “Joint” means joining pipes by adhesive bonding, laminating, welding, etc.


6.2.1 Approval Application Applicant, in case wherever approval, is to submit to the Society (Head Office) together with the application for approval of non-metal pipes (Form 6-4) and the documents specified in 6.2.3.

6.2.2 Applicant Applicant is, in principle, to be the manufacturer. However, any person who is solely responsible for the product quality may serve as applicant.

6.2.3 Documents to be attached The documents to be attached to the approval application specified in the preceding 6.2.1 are to contain the following items: (1) General information:

(a) Pipe and fitting dimensions (b) Design pressure (Maximum internal and external working pressure) (c) Design temperature (Working temperature range) (d) Intended services and installation locations (e) The level of fire endurance (f) Electrically conductive (g) Intended fluids (h) Limits on flow rates (i) Serviceable life (j) Installation instructions (including precautions at work site, repair procedures and criteria for determining

whether repairs are necessary or not) (k) Details of marking

(2) Drawings and supporting documentation: (a) Certificates and reports for relevant tests previously carried out. (b) Details of relevant standards. (c) All relevant design drawings, catalogues, data sheets, calculations and functional descriptions. (d) Fully detailed sectional assembly drawings showing pipe, fittings and pipe connections.

(3) Materials: (a) The resin type. (b) Catalyst and accelerator types, and concentration employed in the case of reinforced polyester resin pipes

or hardeners where epoxide resins are employed. (c) A statement of all reinforcements employed where the reference number does filament winding process,

these are to be detailed.


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(e) Full information regarding the type of gel-coat or thermoplastic liner employed during construction, as appropriate.

(f) Cure and post-cure conditions (including the cure and post-cure temperatures and times). (g) Resin/reinforcement ratio. (h) Winding angle and orientation.

(4) Process of manufacture (5) Outline of the manufacturing factory (6) Quality control system with descriptions on the following items:

(a) Custody of raw materials (place of storage, temperature control, humidity control, storage period, etc.) (b) Work process control (temperature and humidity in the premises of the plant) (c) Inspection system and organization of inspection department (inspection and test before onboard)

(7) Outline of quality system (8) Storage means of products (9) Packing, packaging and marking methods (10) Strength of pipes against bending, twisting, and strength of bonded section against shearing force, resistance

against abrasions by sand, sludge, etc.. Data on types of joint and working procedures. In the data, those relating to bending strength and fatigue strength at standard bends and joints are to be included.

(11) The bonding procedure of making bonds is to include: (a) Material used (b) Tools and fixtures (c) Joint preparation requirements (d) Cure temperature (e) Dimensional requirements and tolerances (f) Tests acceptance criteria upon completion of the assembly

(12) Other data and information as deemed necessary by the Society

6.3 Assessment of Manufacturing and Quality Control Procedure

1 The assessment of manufacturing and quality control procedure is carried out after examination of the documents submitted for approval. However, this assessment may be omitted where deemed appropriate by the Society. 2 The assessment of manufacturing and quality control is carried out to ensure whether the manufacture has the sufficient capability (manufacturing facilities. technical capacity, organizations for quality control and test and inspection system) to keep continuously a stable quality level with the efficient quality control system.

6.4 Approval Tests for Process of Manufacture

The approval tests for process of manufacture are to be carried out in the presence of the Society's surveyor by the method under the testing standard specified in 6.9 or the method considered to be equivalent by the Society. However, when tests are carried out by the authorized organization or any organization considered appropriate by the Society, those on testing items other than strength test, electric conductivity test, heat dependence test of material, flame spread test and fire endurance test may be carried out in the absence of the Society's surveyor.


When the Society considers the product on which the approval is requested has sufficient property for piping system for ships by the results of examination of documents and factory inspection, the Certificate of Approval is issued by the Society. The Certificate is valid for five years.


6.6.1 Announcement of Approval The plastic pipes approved by the Society are to be marked with the following.

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(1) Type of product or trade name (2) Mark to prove that the product is approved by the Society. It may be marked simply by NK. (3) Nominal pressure, [G] for these with low flame spread characteristics, [D] for those with electric conductivity,

material of which pipe or fitting is made (4) Fire endurance level for those with fire endurance

6.7 Quality Control

6.7.1 Quality Control 1 The quality system is to consist of elements necessary to ensure that pipes and fittings are produced with consistent and uniform mechanical and physical properties. 2 The quality control of products including the control of the approved process of manufacture of plastic pipes and various in-house tests is to be carried out under the responsibility of the manufacturer or the applicant to guarantee the quality of products. The records of shop test should be prepared for submission to the Society when required by the surveyor or to the Society. 3 In case where changes are made in the materials composing the approved items or in the process of manufacture, the notice stating the contents of change is be immediately informed to the Society.

6.8 Continuance or Retraction of Approval

6.8.1 Procedures for Continuance of Approval The applicant, when he intends to continue the approval of plastic pipes, is to submit an Application for Approval of Non-metal Pipes (Specimen Form 6-5) (in case where omission of periodical test is desired, the Application for Omission of Periodical Test describing the reasons) to the Society (Head Office). In either case, these documents are to be accompanied by the past records on the product and records of shop tests, each in duplicate (one each for the Head Office and Survey Office, however, if manufacturing plants are located in two or more Survey Offices, additional copies for such extra offices are to be provided).

6.8.2 Periodical Tests Of those testing items for periodical tests specified in the Approval Test Standard for Process of Manufacture, the internal pressure test, external pressure test and tensile test are all to be carried out in the presence of the Society’s surveyor. However, in case where the Society considers unnecessary, the periodical tests may be omitted.

6.8.3 Interval and Postponement of Periodical Tests Periodical test is to be carried out within 5 years from the day of the first approval or the day of the last periodical test.

6.8.4 Occasional Confirmation The Society may request the occasional confirmation test in case where either of the following is relevant. The verification test is to be carried out in the procedure as deemed appropriate by the Society in each case. (1) When the quality of product casts doubt on the basis of the service results of the product (2) When the Society considers necessary due to changes in materials composing the product, process of

manufacture or method of use (3) Other cases as deemed necessary by the Society

6.8.5 Revocation of Approval The Society may revoke approval in case where either of the following items are found relevant : (1) When the product failed to pass the requirements at periodical test or confirmation test (2) When the manufacturer failed to apply periodical test or confirmation test without reasons (3) When application is submitted by the manufacturer for withdrawal (4) When changes are made in the quality of product ascertained at time of approval due to intentional or lack of

enforcement of the quality control (5) When discrepancies are found between the actual and stated contents of product due to intention or negligence (6) When the applicant dose not pay the testing fees or expenses


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(7) In other cases where the Society considers the continuance of approval is inadequate.

6.9 Testing Procedures and Criteria

6.9.1 Criteria for Approval Test for Process of Manufacture The requirements and the criteria for the approval tests are, in principle, referred to Table 6.6. For application of the tables, see below : (1) Those asterisked in the column of criteria represent the items where acceptance criteria do not apply. These data

are for reference only for shop test, piping design, etc. (2) Flame spread, fire endurance and durability against test in Table 6.6 are to be carried out, where they are

required in the Annex D12.1.6-2, Part D of the Guidance for the Survey and Construction of Steel Ships. (3) Where testing method other than those given in Table 6.6 is employed, it may be judged as deemed appropriate

by the Society in consideration of the equivalency. (4) Judgements for acceptance are to be made in accordance with the following procedures and criteria :

(a) For flame spread, judgement is to be made on each of the three test specimens. (b) For heat dependence of material, the acceptance criteria are to be satisfied by the mean value of the three

specimens or at least that of two test specimens. (c) For other test items, the number of specimen and the way for judgment are to be in accordance with each

testing standard.

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Table 6.6 Requirements and Criteria of Approval Test for Process of Manufacture of Plastic pipes Test item Testing method Criteria

Strength against internal pressure of pipe (Short-time and long-time hydraulic failure pressure)

ASTM D1599, ASTM D2992, ISO 15493

*

Strength against external pressure of pipe （collapse pressure）

ASTM D 2924 *

Tensile strength ASTM D2105, ASTM D2990 * Load deformation ASTM D2412 *

Impact resistance ISO 9854, ISO 9653, ISO 15493, ASTM D2444

*

Heat dependence of material ISO 75 Method A (JIS K 7191 Method A), ISO 306 (JIS K 7206), ISO 2507

Minimum heat distortion temperature ≥ 80°C Permissible working temperature depending on the working pressure ≤（ Minimum heat distortion temperature -20°C）

Aging Manufacturer's standard or ISO 9142 *

Fatigue Manufacturer's standard or service experience

*

Fluid absorption ISO 8361 *

IMO Res. A.753(18) Appendix 3 To have low surface flame spread characteristics not exceeding average values listed in the FTP Code, Annex 1 Part 5.

Flame spread

ASTM D 635 HB

Fire endurance IMO Res. A.753(18) Appendix 1, 2

L1: Fire endurance test (IMO Res. A753(18) Appendix 1) in dry conditions, 60 min

L2: Fire endurance test (IMO Res. A753(18) Appendix 1) in dry conditions, 30 min

L3: Fire endurance test (IMO Res. A753(18) Appendix 2) in wet conditions, 30 min

Electric conductivity ASTM F 1173, ASTM D 257, NS 6126 para. 11.2

Surface electrical resistance less than 1MΩ

Material compatibility ASTM C581 or Manufacturer's standard * Note:

“FTP Code” means the “INTERNATIONAL CODE FOR APPLICATON OF FIRE TEST PROCEDURES”, as adopted by the Maritime Safety Committee of the International Maritime Organization by resolution MSC.61(67) adopted on 5 December 1996.


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Form 6-4

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Form 6-5


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Chapter 7 APPROVAL OF VENTING SYSTEMS AND RELATED EQUIPMENT FOR OIL TANKERS

7.1 General

7.1.1 Scope In accordance with the requirements of 4.5.3 and 11.6, Part R of the Rules for the Survey and Construction of Steel Ships, the requirements in this Chapter apply to tests and inspections for the type approval of venting systems and related equipment for oil tankers.

7.1.2 Definitions For the purpose of this chapter, the following definitions (1) through (8) apply : (1) “PV valve” is a device designed to maintain pressure and vacuum in a closed container within preset in limit

conformity with the requirements in 11.6.1, Part R of the Rules for the Survey and Construction of Steel Ships.

(2) “Flame screen” is a device utilizing wire mesh to prevent the passage of unconfined flames in conformity with the related requirements in 4.5.3-3, Part R of the Rules for the Survey and Construction of Steel Ships.

(3) “Flame arrester” is a device to prevent the passage of flame by elements based on the principle of quenching in conformity with the related requirements in 4.5.3-3, Part R of the Rules for the Survey and Construction of Steel Ships.

(4) “Detonation flame arrester” is a device to prevent the passage of flame generated in association with a detonation in the line pipe in conformity with related requirements in 4.5.3-3, Part R of the Rules for the Survey and Construction of Steel Ships.

(5) “High velocity device” is a device to prevent the passage of flame consisting of a mechanical valve which adjust the opening available for flow in accordance with the pressure at inlet of the valve in such a way that the efflux velocity can not be less than 30 m/s in conformity with related requirements in 4.5.3-3, Part R of the Rules for the urvey and Construction of Steel Ships.

(6) “High level alarm system” is a device which alarms of excessive rises in the liquid cargo level to guard liquid rising in the venting system to the height which would exceed the designed head of cargo tanks in conformity with the requirements in 11.6.3-1, Part R of the Rules for the Survey and Construction of Steel Ships.

(7) “Rupture disc” is a pressure relief device of a bursting disc type or a mechanical function type to prevent over-pressure and/or under-pressure during cargo loading and ballasting or discharging operations, and to work when the tank pressure reaches to a set pressure in conformity with related requirements in 11.6.1, Part R of the Rules for the Survey and Construction of Steel Ships.

(8) “Pressure monitoring system” is a device to prevent over-pressure and/or under-pressure during cargo loading and ballasting or discharging operations, and to monitor the tank pressure and to actuate an alarm when the tank pressure reaches to a set pressure in conformity with related requirements in 4.5.3-2(3), Part R of the Rules for the Survey and Construction of Steel Ships.


7.2.1 Application Form for Approval Those desiring approval for venting systems and related equipment for oil tankers are requested to submit a single copy of the Application (Specimen Form 6-6) filled in with necessary data and information to the Society.

7.2.2 Application Procedure 1 Those submitting the Application Form of the preceding 7.2.1, as a rule, should be the manufacturer of the devices concerned, although exceptions are made for parties who have ultimate responsibility for quality assurance of the devices concerned.

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2 Manufacturers of the parts of the devices concerned may become the applicant in case where approval, as specified in this chapter, for the parts is desired.

7.2.3 Data to be Submitted Three copies of the data given in the following (1) through (9) are to be submitted together with the Application Form referred to in 7.2.1. (1) Specifications of the equipment (2) Construction drawing and summary of working principles of the equipment (3) Approval test plan (with location and scheduled date of test) (4) Data on summary of equipment used in the above test (5) Data on outline of manufacturing plant (6) Data on manufacturing and quality control of the equipment (7) Manufacturing and delivery records of the equipment (8) Data on technology of the equipment (9) Other data deemed necessary by the Society


7.3.1 Approval of Test Plan The Society examines test plans submitted for approval in accordance with the requirements in 7.2.3(3) and, when deemed appropriate, approves and returns the test plans to the applicant. In this case, data submitted in accordance with 7.2.3 are studied and, where no negative effects are recognized, parts of the approval test may be dispensed with.

7.3.2 Confirmation of Manufacturing and Quality Control Procedure When deemed necessary, the Society may conducts surveys of the actual situation at the manufacturing plant according to data submitted in accordance with 7.2.3(4), (5), (6), (7) and (8).

7.4 Approval Test

7.4.1 Test Product The test products used in the approval test are to be of each configuration and dimension given in the application.

7.4.2 Details of Tests and Inspections 1 PV valves (1) General

(a) Materials and strength, construction, and tests and inspections of a PV valve are to be in accordance with the requirements in the following (2) through (4).

(b) After carrying out a corrosion test and a hydraulic test, an operation test and a general inspection are to be carried out on the same specimen. An example of testing equipment for the operation test is shown in Fig. 6.7-1.

Fig. 6.7-1 Example of Testing Equipment for PV Value


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(2) Materials and strength (a) All materials for constructing PV valves are to be resistant to corrosion and heat and to be suitable for the

circumstances of both seawater and the carried cargoes. (b) The valve bodies are to have equivalent strength, heat resistance and corrosion resistance to the pipes to

which they are attached. (c) The valve bodies, the valve discs and the valve seats are to be capable of withstanding the highest pressure

and temperature to which they may be exposed under normal service and specified test conditions. (d) Springs coated with corrosion-resistant material are not regarded to comply with (a) above. (e) Non-metallic materials, other than gaskets and seals, are not to be used in the construction of

pressure-retaining components of the device. (f) Non-metallic materials used for the construction other than those described in (e) above are to be made of

non-combustible material suitable for the intended service. (g) The possibility of galvanic corrosion is to be considered in the selection of materials.

(3) Construction (a) All flat joints of the housing are to be machined true and to be provided for a joint having an adequate

metal-to-metal contact. The device housings is to be gastight in the primary pressure zone upstream of the main valve seat to prevent the escape of vapours. Resilient-seating seals may be provided if the design is such that the disc closes tight against the seat in case the seals are destroyed, damaged or otherwise carried away.

(b) The valves are to allow for the easy inspection of the entire device and internal elements (including a check to verify the valve lifts smoothly without remaining in the open position), cleaning, repair or removal. The design is not to allow the valve to be incorrectly reassembled after a disassembly.

(c) The valves are to be designed such that condensed vapours are easily drained off without loss of function to prevent the passage of flames. The design is to also prevent the accumulation of water or condensed vapours inside the device and subsequent blockage due to freezing. Where the design does not permit complete drainage of condensed vapours through its connection to the tank, the housing is to be fitted with a plugged drain opening on the side of the atmospheric outlet of not less than 13 mm in diameter.

(d) The essential fastenings are to be protected against loosening. (e) The valves are to be capable of operating in a freezing condition (such as may cause blockage by frozen

cargo vapours or by icing in bad weather) and if any device is provided with heating arrangements so that its surface temperature exceeds 85, then it is to be operable at the highest surface temperature.

(f) Devices are to be designed and constructed to minimize the effect of fouling under normal operating conditions.

(g) End-of-line devices are to be so constructed as to direct the efflux vertically upwards. (h) Valve discs are to normally close against the valve seat by metal-to-metal contact. The discs are to be

guided by a suitable means to prevent binding and ensure proper self-closing (seating), taking into account the possible build-up of condensed vapours passing through the valve during loading. A clear indication, visible from the outside of the valve, is to be provided to indicate the position of the valve.

(i) Valves may be actuated by non-metallic diaphragms except where failure would result in unrestricted flow of tank vapours to the atmosphere or in an increase in the pressure or vacuum at which the valve normally opens.

(j) Relief pressure adjusting mechanisms are to be permanently secured by lockwires, locknuts or other suitable means to prevent devices from becoming misadjusted due to handling, installation or vibration.

(k) The performance characteristics, such as flow rates under both positive and negative pressures, operating sensitivity, flow resistance and velocity, are to be demonstrated by appropriate tests. In this case the presence of the Society's surveyor may be dispensed with.

(4) Tests and inspections (a) Corrosion test

A corrosion test is to be carried out under the following conditions in accordance with the recognized standards, e.g. JIS Z 2371. Following this test, it is to be verified that all movable parts are operable properly and there is no corrosion deposit that cannot be washed off. i) Consistency of the sodium chloride solution : 5 %

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ii) Testing temperature : 25 iii) Exposing time in the solution spray : 240 hours iv) Drying time : 48 hours

(b) Hydraulic test The pressure-retaining boundary of the device is to be subjected to a hydrostatic-pressure test of at least 150% of maximum rated pressure (MRP) or a minimum pressure of 0.345 MPa gauge (50 psig), whichever is greater, for ten minutes without rupturing, leaking or showing permanent distortion.

(c) Operation test An operation test specified in clause 12, ISO 15363 is to be carried out to ascertain the following items. In this case, the operational errors are to be in ranges from 0 to -10% of the set pressure on the pressure side and from +10% to 0 of the set pressure on the vacuum side. Where air or gas other than the vapours of cargoes to be carried is employed in the test, the result achieved is to be corrected to reflect the vapour density of such cargoes. i) Suction and discharge rates ii) Pressures at which the valve opens and closes iii) Flow resistance that can be calculated by the result of i) and ii) above.

(d) Finish inspection When all finished, a general inspection is to be carried out to ascertain the materials, construction and dimensions of the valve, and to be pneumatically tested at 0.07 MPa (10 psi) either using a submerged test or a soap test for a duration of three minutes to ensure there is no leakage.

2 Flame screens, flame arresters, detonation flame arresters and high velocity vents (1) General

(a) Materials and strength, construction and dimension, and tests and inspections of a flame screen, a flame arrester, a detonation flame arresters and a high velocity vent are to be in accordance with the requirements in the following (2) through (4).

(b) For flame screens, after carrying out a corrosion test and a hydraulic test, a flashback test and a general inspection are to be carried out. The test component is not to be exchanged for each test requested and is to have the most inappropriate gap dimension expected in the service of the product. An example of testing equipment for the flashback test is shown in Fig. 6.7-2.

(c) For flame arresters, after carrying out a corrosion test and a hydraulic test, a flashback test, an endurance burning test and a general inspection are to be carried out. The test component is not to be exchanged for each test requested and is to have the most inappropriate gap dimension expected in the service of the product. An example of testing equipment for the flashback test is shown in Fig. 6.7-2.

(d) For detonation flame arresters, after carrying out a corrosion test and a hydraulic test, a detonation test, an endurance burning test and a general inspection are to be carried out. The test component is not to be exchanged for each test requested and is to have the most inappropriate gap dimension expected in the service of the product. An example of testing equipment for the detonation test is shown in Fig. 6.7-3.

(e) For high velocity devices, after carrying out a corrosion test and a hydraulic test, a flow volume test, a flashback test, an endurance burning test and a general inspection are to be carried out. The test component is not to be exchanged for each test requested and is to have the most inappropriate gap dimension expected in the service of the product. Examples of testing equipment for the flashback test, and the flow volume test and the endurance burning test are shown in Fig. 6.7-4 and Fig. 6.7-5 respectively.


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Fig. 6.7-2 Example of Testing Equipment for Flame Arrester

Fig. 6.7-3 Example of Testing Equipment for Detonation Flame Arrester

Fig. 6.7-4 Example of Testing Equipment for High Speed Discharger (For flashback test)

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Fig. 6.7-5 Example of Testing Equipment for High Speed Discharger

Notes :

1. Blower (variable flow volume 1 flow speed) 2. Flow volume meter 3. Pipe (500 mm diameter). less than 30 m in length 4. Heated vapour pipe 5. Air bypass pipe 6. Evaporator and liquid storage tank 7. Vapour - air mixture bypass pipe 8. Fire extinguishing medium 9. Emergency shut - off and control valve 10. Crimped ribbon type explosion prevention device with temperature control device for safety 11. High speed discharger 12. Fire detector 13. Diaphragm 14. Concentration meter 15. Tank

(2) Materials and strength

(a) All materials for constructing the devices are to be resistant to corrosion and heat and to be suitable for the circumstances of both seawater and the carried cargoes.

(b) The casings of the device are to have equivalent strength, heat resistance and corrosion resistance to the pipes to which they are attached.

(c) The casings, the elements and the gaskets are to be capable of withstanding a pressure and a temperature to which the device may be exposed under both normal service condition and specified fire test condition.

(3) Construction and dimension (a) General

i) The devices are to allow for easy inspection of the entire device and internal elements, cleaning, repair or removal.

ii) The valves are to be designed such that condensed vapours are easily drained off without loss of function to prevent the passage of flames.

iii) The essential fastenings are to be protected against loosening. iv) Devices are to be designed and constructed to minimize the effect of fouling under normal operating

conditions. v) All flat joints of the housing are to be machined true and to be provided for a joint having an adequate

metal-to-metal contact.


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vi) Resilient-seating seals may be provided if the design is such that the disc closes tight against the seat in case the seals are destroyed, damaged or otherwise carried away.

vii) End-of-line devices are to be so constructed as to direct the efflux vertically upwards. viii) The valves are to be capable of operating in a freezing condition (such as may cause blockage by

frozen cargo vapours or by icing in bad weather) and if any device is provided with heating arrangements so that its surface temperature exceeds 85, then it is to be operable at the highest surface temperature.

ix) The elements are to be protected against mechanical damages. x) The performance characteristics, such as flow rates under both positive and negative pressures,

operating sensitivity, flow resistance and velocity, are to be demonstrated by appropriate tests. In this case the presence of the Society's surveyor may be dispensed with.

(b) Flame screens, flame arresters and detonation flame arresters i) The clear area through the element is to be at least 1.5 times the cross-sectional area of the vent line. ii) The elements are to be secured in the casing in such a way that flame cannot pass between the element

and the casing. (c) High velocity devices

i) High velocity devices are to have a width of the contact area of the valve seat of at least 5 mm. ii) A means is to be provided to verify the valve lifts smoothly without remaining in the open position.

(4) Tests and inspections (a) General

i) Tests and inspections specified in this (4) are to be carried out for each type and size of the device. ii) Tests specified in this (4) are to be carried out by a laboratory accepted by the Society. iii) For devices to be installed in ships dedicated to the carriage of products, for which IIB or IIC is

marked in the column i’’ of Table S17.1, Part S of Rules for the Survey and Construction of Steel Ships, a flashback test and an endurance burning test are to be carried out with appropriate media.

iv) For devices with a heating arrangement whose surface temperature exceeds 85, tests specified in (b) through (f) are to be carried out at the maximum operating temperature.

v) For devices to be fitted in a venting system for cargo oil tanks protected against a flammable condition by an inert gas system complying with Chapter 35, Part R of Rules for the Survey and Construction of Steel Ships, an endurance burning test may be dispensed with. In this case, such devices are to be expressed with “non endurance burning type”.

vi) When a PV valve is integrated to a flame arrester, the flashback test is to be carried out with the PV valve blocked open.

vii) For flame arresters to be fitted in ships other than those of 500 gross tonnes or more engaged in international voyages, an endurance burning test may be dispensed with. And for high velocity devices to be fitted in such ships, a flashback test and an endurance burning test may be dispensed with. In this case, such arresters are to be expressed with “non endurance burning/non flashback proof type”.

(b) Tests for flame arresters located at openings to the atomosphere The following tests are to be carried out to ascertain that no flashback occurs. In order to avoid remnants of the plastic bag from falling back on to the device being tested after ignition of the fuel/air mixture, it may be useful to mount a coarse wire frame across the device within the plastic bag. The frame is to be so constructed as not to interfere with the test result. In these tests, the attachments such as cowls, weather hoods, deflectors, etc. are to be fitted to the end of the flame arrester. i) Flashback test

A flashback test is to be carried out in accordance with the following: 1) The tank, the flame arrester assembly and the plastic bag enveloping the flame arrester are to be

filled with the most easily ignitable propane/air mixture. 2) The concentration of the mixture is to be verified by appropriate testing of the gas composition in

the plastic bag. 3) Three ignition sources are to be installed along the axis of the bag, one close to the flame arrester,

another as far away as possible therefrom, and the third at the midpoint between these two. 4) These three sources are to be fired in succession, twice in each of the three position.

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5) The temperature of the test gas is to be within the range of 15 to 40. ii) Endurance burning test

An endurance burning test is to be carried out in accordance with the following: 1) Without the plastic bag the flame arrester is to be so installed that the mixture emission is vertical. 2) Endurance burning is to be achieved by using the most easily ignitable gasoline vapour/air

mixture or the most easily ignitable technical hexane vapour/air mixture with the aid of a continuously operated pilot flame or a continuously operated spark igniter at the outlet.

3) Maintaining the concentration of the mixture as specified in 2), by varying the flow rate, the flame arrester is to be heated until the highest obtainable temperature on the cargo tank side is reached. This temperature is to be maintained for a period of 10 minutes, after which the flow is to be stopped and the conditions are to be observed. The highest obtainable temperature may be considered to have been reached when the rate rise of temperature does not exceed 0.5 per minute over a ten-minute period. If difficulty arises in establishing stationary temperature conditions (at elevated temperatures), endurance burning, by using the flow rate which produced the maximum temperature during the foregoing test sequence, is to be continued for a period of two hours from the time the above mentioned flow rate has been established.

(c) Tests for flame arresters located in-line The following tests are to be carried out to ascertain that no flashback occurs. In these tests, the flame arrester is to be tested with the inclusion of all pipes, tees, bends, cowls, weather hoods, etc. which may be fitted between the device and atmosphere. i) Flashback test

A flashback test is to be carried out in accordance with (b)i). In this test, the plastic bag is to be fitted at the outlet to atmosphere.

ii) Endurance burning test An endurance burning test is to be carried out in accordance with (b)ii). In this test, the flame arrester is to be so installed as to reflect its final orientation.

(d) Tests for detonation flame arresters located in-line The following tests are to be carried out to ascertain that no flashback occurs and no part of the flame arrester is damaged or shows permanent deformation. i) Detonation test

1) A detonation flame arrester is to be installed at one end of a pipe, and a plastic bag is to be affixed on the other end of the detonation flame arrester.

2) The tank, the plastic bag, the pipes and the detonation flame arrester are to be filled with the most easily ignitable propane/air mixture.

3) They are to be ignited in the tank and three detonation tests are to be carried out. The velocity of the flame measured near the detonation flame arrester is to have a value of that for stable detonations.

ii) Endurance burning test In case where the distance requirement in R4.5.3-3(3)(c), Part R of Guidance for the Survey and Construction of Steel Ships cannot be met, an endurance burning test is to be carried out in addition to the requirement in i).

(e) Tests for flame screens A flashback test is to be carried out in accordance with (b)i) or (c)i) depending on the installed position of the flame screen.

(f) Tests for high velocity devices i) Flow condition test

A flow condition test is to be carried out with high velocity vents using compressed air or gas at agreed flow rates, and the following is to be measured and recorded.

1) The flow rate. Where air or gas other than vapours of cargoes with which the vent is to be used is employed in the test, the flow rates achieved are to be corrected to reflect the vapour density of such cargoes.

2) The pressure before the vent opens. The pressure in the test tank on which the device is located is


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not to rise at a rate greater than 0.01 MPa/min. 3) The pressure at which the vent opens. 4) The pressure at which the vent closes. 5) The efflux velocity at the outlet which is not to be less than 30 m/s at any time when the valve is

open. ii) Flashback test

A flashback test is to be carried out in accordance with the following to ascertain that no flashback occurs.

1) The test rig and the high velocity device are filled with the most easily ignitable gasoline vapour, hexane vapour or propane/air mixture. The mixture is to be ignited with the aid of a permanent pilot flame or a spark igniter at the outlet. A flashback test is to be carried out with the device in the upright position and then inclined at 10°from the vertical. For some device designs further tests with the device inclined in more than one direction may be necessary.

2) In each of these tests specified in 1), the flow is to be reduced until the device closes and the flame is extinguished, and each is to be carried out at least 50 times.

iii) Endurance burning test An endurance burning test is to be carried out in accordance with the following to ascertain that no flashback occurs.

1) An endurance burning test is to be carried out in accordance with (b)ii). 2) Following the test specified in 1), the main flame is to be extinguished and then, with the pilot

flame burning or the spark igniter discharging, small quantity of the most easily ignitable mixture is to be allowed to escape for a period of 10 minutes maintaining a pressure below the value of 90% of the valves opening setting.

3) For the purpose of this test, soft seals and seats are to be removed. (g) Corrosion test

A corrosion test specified in 7.4.2-1.(4)(a) is to be carried out for a complete device including a section of the pipe on which the device is fitted. This test is to be carried out before the tests specified in (b) through (f).

(h) Hydraulic test For the casing of a device, a hydraulic test at the same test pressure as the pipe to which the device is attached. This test is to be carried out before carrying out the tests specified in (b) through (f).

(i) Finished inspection When it finished, a general inspection is to be carried out to ascertain the materials, construction and dimensions of the valve.

3 High level alarms and level detecting devices of an overflow control system (1) General

Performance and construction, and tests and inspections of a high level alarm and a level detecting device of an overflow control system are to be in accordance with the requirements in the following (2) and (3).

(2) Performance and construction (a) The deviation between the indicated level and the actual one is to be within ± 25 mm or less. (b) The liquid level can be indicated within a time lag of 3 seconds following the actual liquid level fluctuation. (c) The device is to be capable of withstanding motions, vibrations and inclinations of a ship. (d) Electrical installations of the device are to comply with the requirements in 4.3, Part H of Rules for the

Survey and Construction of Steel Ships. (e) Due consideration is to be paid against the generation of static electricity. (f) The device is to be capable of withstanding the highest pressure and temperature to which the device may

be exposed under normal condition, and is to be of material resistant both sea water and cargoes carried. (g) The construction of a device is to be in accordance with the following requirements:

i) The design is to allow for ease of repair. ii) The fastenings are to be protected against loosening.

(h) The operational error is to be demonstrated by an appropriate test. (i) The alarms are to be visible and audible, and to be capable of identifying the tank in which the liquid level

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rises. (j) The audible alarm is to be capable of being stopped manually.

(3) Tests and inspections High level alarms and level detecting devices of an overflow control system are to comply with the requirements specified in Chapter 4, Part 7. In application of Chapter 4, Part 7, a reference to “level indicator” is to be deemed to mean a reference to “high level alarms and level detecting devices of an overflow control system”.

4 Rapture discs (1) General

(a) Materials and strength, construction of rapture discs are to be in accordance with the requirements in the following (2) and (3). When deemed necessary by the Society, the confirmations specified in following (6) are to be carried out.

(b) In addition to the requirements in (a), the rupture disc of a bursting disc type is to be of a type in compliance with JIS B 8226 “Bursting Discs and Bursting Disc Assemblies” or other recognized standard deemed appropriate by the Society. Where a bursting disc is exposed, tests and inspections specified in JIS B 8226 are to carried out on the same specimen after carrying out a corrosion test specified in following (5)(a).

(c) In addition to the requirements in (a), the strength, tests and inspections for the rupture disc of a mechanical function type is to be in accordance with following (4) and (5). Tests and inspections for the rupture disc of a mechanical function type is to be carried out on the same specimen after carrying out a corrosion test and a hydraulic test.

(2) Materials The materials are to be suitable for sea water and cargoes to be carried.

(3) Construction (a) A rupture disc is to be capable of operating in a freezing condition. (b) A rupture disc is to allow for easy inspections. (c) Where non-metallic membranes are used as bursting discs, these non-metallic membranes are to have the

durability over 3 years under the expected working conditions. (4) Strength

(a) The casings of a device are to have equivalent strength, heat resistance and corrosion resistance to the pipes to which they are attached.

(b) The device is to be capable of withstanding a pressure and a temperature to which the device may be exposed under normal working condition.

(5) Tests and inspections (a) Corrosion test

A corrosion test is to be carried out in accordance with JIS Z 2371 or other recognized standard deemed appropriate by the Society, and the compliance with them is to be ascertained.

(b) Hydraulic test For the casing of a device, a hydraulic test at a pressure of 1.5 times the set pressure on the pressure side for a period of 1 minute is to be carried out with a satisfactory result.

(c) Operation test i) An operation test is to be carried out to ascertain the following items. In this case, the operational

errors are to be in ranges from 0 to -10% of the set pressure on the pressure side and from +10% to 0 of the set pressure on the vacuum side.

ii) A device is to be able to ensuring the maximum pressure relieving rate at the same time as a device starts to work.

(d) Finished inspection When it finished, a general inspection is to be carried out to ascertain the materials, construction and dimensions of a device.

(6) Confirmation of pressure relieving rate, etc. (a) The pressure relieving rate (b) Flow resistance

5 Pressure monitoring system


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(1) General Construction, strength, tests and inspections of a pressure monitoring system are to be in accordance with the requirements in the following (2) and (3).

(2) Construction (a) A pressure monitoring system is to comply with the requirements specified in 4.4.1 of Part 7. In

application of 4.4.1 of Part 7, a reference to “level indicator” is to be deemed to mean a reference to “pressure monitoring system”.

(b) In addition to the requirements specified in (a), a pressure monitoring system is to be in accordance with followings: i) The alarms are to be visible and audible, and to be capable of identifying the tank which is the

condition of over-pressure or under-pressure. ii) The audible alarm is to be capable of being stopped manually.

(3) Tests and inspections (a) The details of tests are to be in accordance with the requirements specified in 4.4.2 of Part 7. (b) In addition to the requirements specified in (a), a pressure monitoring system is to be in accordance with

followings: i) The operational errors are to be in ranges from 0 to -10% of the set pressure on the pressure side and

from +10% to 0 of the set pressure on the vacuum side. ii) The pressure can be measured within a time lag of 3 seconds following the actual pressure fluctuation.

7.4.3 Attendance of the Society’s Surveyor for Test As a rule, the surveyor of the Society is to be present when the approval test is being conducted. However, the surveyor of the Society may not have to be present when performing the given test at a recognized official organization deemed appropriate by the Society.

7.4.4 Record of Test 1 After completion of the approval test, the manufacturer is to produce a record of the approval test and is to submit three copies to the Society upon receiving confirmation by the surveyor of the Society. 2 Where the provision of the preceding 7.4.3 applies, the test record produced by the recognized official organization may substitute for the conformation by the surveyor of the Society. 3 The record of the approval test of the preceding -1 and -2 is to include the following items and to be appended with the records relating to the quality control implemented during the manufacturing process for the test products. (1) Detailed drawings of the device; (2) Kind of tests conducted and the results obtained, with all recorded data;. (3) Specific notice on approved attachments; (4) Types of cargoes for which the device has been approved; (5) Drawings of the test rig, including a description of the attached inlet and outlet piping; (6) All the information marked on the device in 7.6.2.

7.5 Approval

7.5.1 Notification and Announcement of Approval 1 The Society grants approval for eliminating a part of the test specified in 7.4 against venting systems and related equipment for oil tankers as deemed appropriate in accordance with data submitted according to the requirement in 7.2 through 7.4 and on reports of the surveyor. In this case, the “Notice of Approval” is published including the approval number, approval date, approval items, approval conditions etc. and, at the same time, among those drawings and documents submitted in accordance with the requirements in 7.2.3 and 7.4.4, which the Society deems necessary, a seal of approval is stamped and returned to the applicant. 2 Once a year, the Society makes an announcement, in the form of a list, of venting systems and related equipment for oil tankers which conform to the requirements in this chapter.

7.5.2 Period of Validity The period of validity of approval in accordance with the requirements in this chapter is not to exceed four years

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from the date of approval.

7.5.3 Changes in the Contents of Approval 1 Manufacturers desiring continued application of the requirements in this chapter against equipment which have exceeded the period of validity or have undergone changes in the content of approval are to submit a copy of the Approval Continuation Application Form (Specimen Form 6-7) and are to proceed with the application process by the following requirements in 7.2. 2 When approval has been granted to an application with partial changes in the content of approval, as a rule, the period of validity is not renewed.

7.5.4 Revocation of Approval In case any of the following (1) through (4) is relevant, the Society may revoke the approval in accordance with the requirements in this chapter and give notice of revocation to the manufacturers. (1) When approval renewal procedures were not taken up without any special reason (2) When the equipment, which has already been granted approval in accordance with the requirements is this

chapter, no longer conforms to the relevant requirements due to implementation and amendment of conventions, laws, rules and regulations.

(3) When a major inconvenience is introduced in the construction or quality of the equipment concerned, which have been approved in accordance with the requirements in this chapter, after the equipment have been erected in the ship.

(4) When a request for revocation is made by the manufacturer.

7.6 Handling after the Approval

7.6.1 Tests and Inspection on the Individual Product The tests and inspection for the individual product whose prototype has been approved are to be carried out in accordance with the following (1) through (6) in the presence of the surveyor of the Society at manufacturing plant prior to shipment. (1) PV valves

(a) Confirmation of the pressures at which the valve opens and closes (b) Hydraulic test (to be carried out before carrying out the test of (a)) (c) Finished inspection

(2) Flame screens, flame arresters and detonation flame arresters (a) Finished inspection

(3) High velocity devices (a) Confirmation of the pressure at which the valve opens (b) Hydraulic test (to be carried out before carrying out the test of (a)) (c) Finished inspection

(4) High level alarms and level detecting devices of an overflow control system (a) Confirmation of the deviation, the time lag and the alarm function (b) Hydraulic test in case where the device has a watertight test (c) Finished inspection

(5) Rupture discs The operation tests specified in 7.4.2-4.(5)(c)i) and ii) and the finish inspection specified in 7.4.2-4.(5)(d) are to be carried out. However, for the rupture disc of a bursting disc type, tests and inspection may be limited to those specified in the approved certificate mentioned in 7.5.1-1.

(6) Pressure monitoring systems Tests and inspection may be limited to those specified in the approved certificate mentioned in 7.5.1-1.

7.6.2 Marking On the venting systems and related equipment for oil tankers which have been granted approval in accordance with the requirements of this chapter, in addition to displaying the fact that they are approved products, at least the following matters are to be marked in an appropriate place.


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(1) For PV valves, matters given in the following (a) through (f) : (a) Name of manufacturer or substitute, date of manufacture and serial number (b) Type and configuration (c) Dimensions of opening for installation (d) Direction of installation (e) Set pressure (positive pressure side and negative pressure side) (f) Compliance with MSC/Circ.677.

(2) For flame screens, flame arresters, detonation flame arresters and high speed dischargers, matters given in the following (a) through (f): (a) Name of manufacturer or substitute, date of manufacture and serial number (b) Type and configuration (c) Dimensions of opening for installation, type of opening (i.e. distinction between intake and exhaust) and

position (i.e. for installation in the middle of air duct, includes limit distance from edge of opening) (d) Direction of air flow (e) Name of the test laboratory and test record number (f) Compliance with the requirements of MSC/Circ.677 (Where any test is dispensed with in accordance with

the provisions of 7.4.2-2(4), such condition is to be clearly marked.) (3) For high level alarm system, matters given in the following (a) through (c) :

(a) Name of manufacturer or substitute, date of manufacture and serial number (b) Type and configuration (c) Level of liquid at which alarm is issued

(4) For rupture discs, matters given in the following (a) to (f): (a) Name of manufacturer or substitute, date of manufacture and serial number (b) Type and configuration (c) Dimensions of opening for installation (d) Set pressure (positive pressure side and/or negative pressure side) (e) Direction of installation (f) Material

(5) For pressure monitoring system, matter given in the following (a) to (c): (a) Name of manufacturer or substitute, date of manufacture and serial number (b) Type and configuration (c) Set pressure (positive pressure side and/or negative pressure side)

7.7 Additional Requirements for Equipment Manufactured Overseas

7.7.1 General As a rule, even though given equipment are manufactured overseas, they are still to be in accordance with the requirements in 7.2 through 7.6. However,where this is acknowledged as being difficult by the Society, the equipment may be in accordance with the requirements in 7.7 of this section.

7.7.2 Approval Application 1 Requirements in 7.2 apply. 2 Certificates and performance records published by foreign government organizations and foreign ship classification societies recognized by the Society are to be submitted for the equipment.

7.7.3 Approval Requirements in 7.5 apply.

7.7.4 Sampling Test Where deemed necessary by the Society, test products may be sampled and suitable tests and inspection may be requested for the equipment subject to the application of requirements in 7.7 of this section.

7.7.5 Dealing after Approval Requirements in 7.6 apply.

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Form 6-6


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Form 6-7

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Chapter 8 APPROVAL OF USE OF DIESEL ENGINES

8.1 General

8.1.1 Scope 1 The requirements in this chapter apply to tests and inspection for the approval of use of new type diesel engines intended for the installation at first on board ships which are classed or to be classed with the Society on the basis of the requirements in 2.6.1-4, Part D of the Rules for the Survey and Construction of Steel Ships. 2 Notwithstanding -1 above, a part or whole of the tests and inspection specified in this chapter may be dispensed with when deemed appropriate by the Society in consideration of the service experience of similar type engines, etc. 3 An approval for a particular type of engine of which tests and inspection carried out at any place at any manufacturer will be accepted for all engines of the same type having different number of cylinders built by licensees and licensers. 4 The requirements in this chapter apply, in general, to each engine type of which either of the following is different to that of an approved engine type. (1) Bore (2) Stroke (3) Method of injection (direct or indirect injection) (4) Kind of fuel (liquid, dual-fuel, gaseous) (5) Working cycle (2-stroke, 4-stroke) (6) Gas exchange (naturally aspirated or super-charged) (7) Maximum continuous power per cylinder at maximum continuous speed and/or maximum continuous brake

mean effective pressure (If an approved engine which has proven reliability in service is increased in output by not more than 10% a new approval is not necessary). The agreement for granting an increased output will subject to prior plan approval.

(8) Method of pressure charging (pulsating system, constant pressure system) (9) Charging of cooling system (with or without intercooler, number of stages) (10) Cylinder arrangement (in-line, vee) (11) Control method of fuel injection and exhaust valve drive (electronically-controlled, camshaft driven)

8.2 Application

8.2.1 Application Form The manufacturer who intends to obtain the approval is to submit an application form filled with necessary data and information to the Society (Head Office).

8.3 Approval Tests

8.3.1 Test Stages The approval tests are subdivided into three stages below. (1) Stage A

Functional tests and collection of operating values including test hours during the internal tests, the relevant results (including photographs which show the conditions of each component after the internal tests) of which are to be presented to the Society during the stage B. Testing hours of components which are inspected according to 8.3.2-3 are to be stated.

(2) Stage B Operation test in the presence of the Society’s surveyor.

(3) Stage C


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Component inspections by the surveyor after completion of the test programme. The engine manufacturer will have to compile all results and measurements for the engine tested during the approval tests a report, which will have to be handed over to the surveyor.

8.3.2 Details of Tests 1 During the stage A, the following items of tests are to be included: (1) Operation at the load points 25%, 50%, 75%, 100% and 110% of the maximum rated power and other load

points considered important, at engine speed of: (a) along the nominal (theoretical) propeller curve and at constant speed for propulsion engines (b) at constant speed for engines intended for generating sets or auxiliary machinery

(2) Operation at the limit points of the permissible operating range (3) For turbocharged engines the achievable continuous output is to be determined in the case of turbocharger

damage as follows: (a) engines with one turbocharger, when rotor is blocked or removed (b) engines with two or more turbochargers, when damaged turbocharger is shut off.

(4) If an engine can be satisfactorily operated at all load points without using mechanically driven cylinder lubricators this is to be verified.

(5) For engines which may operate on heavy fuel oil suitability for this will have to be proved in an appropriate form. This test is to be carried out at Manufacturer’s shop in general, but where not practicable, it is acceptable to test on board for the first engine of each series to be put into service.

(6) For electronically-controlled diesel engines, continuous operation tests for the following components are to be carried out to confirm the durability within the period prescribed by the manufacturer. (a) Control valves (b) Accumulator diaphragms

(7) For electronically-controlled diesel engines, the functions included in the software of the control system are to be confirmed.

(8) For electronically-controlled diesel engines, an operation test is to be carried out under one cylinder cut-off condition.

(9) Other items deemed to be verified by the Society. 2 During the stage B, the following items of tests are to be included. Deviations from the items, if any, are to be agreed with the Society. (1) Operation at each load point below (an operating time of two hours is to be required at the load point in (a) and

two sets of readings are to be taken at a minimum interval of one hour, an operating time of 0.5 hour can be normally assumed per each load point other than (a).) (a) Rated power, i.e. 100% output at 100% torque and 100% speed (corresponding to load point 1 in Fig.

6.8-1) (b) 100% power at maximum permissible speed (corresponding to load point 2 in Fig. 6.8-1) (c) Maximum permissible torque (normally 110%) at 100% speed (corresponding to load point 3 in Fig. 6.8-1)

or maximum permissible power (normally 110%) and speed according to nominal propeller curve (corresponding to load point 3a in Fig. 6.8-1)

(d) Minimum permissible speed at 100% torque (corresponding to load point 4 in Fig. 6.8-1) (e) Minimum permissible speed at 90% torque (corresponding to load point 5 in Fig. 6.8-1) (f) Part loads, e.g. 25%, 50%, and 75% of rated power and speed according to nominal propeller curve

(corresponding to load points 6, 7 and 8 in Fig. 6.8-1) for propulsion engines (g) Part loads, e.g. 25%, 50%, and 75% of rated power and rated speed with constant governor setting

(corresponding to load points 9,10 and 11 in Fig. 6.8-1) for engines intended for generator sets or auxiliary machinery

(2) Maximum achievable power when operating along the nominal propeller curve in the case specified in 8.3.2-2(3) for propulsion engine

(3) Maximum achievable power when operating with constant governor setting for rated speed in the case specified in 8.3.2-1(3) for engines intended for generator sets or auxiliary machinery

(4) Lowest engine speed according to nominal propeller curve for propulsion engines

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(5) Starting tests, for non-reversible engines and/or and reversing tests, for reversible engines (6) Governor test (7) Testing the safety system, particularly for overspeed and low lubricating oil pressure (8) Supplementary tests when required for engines intended for emergency services (9) Other test items deemed necessary by the Society 3 During the stage C, immediately after the testrun the components of one cylinder for in-line engines and two cylinders for V-engines are presented for inspections. The following components concerned: (1) Piston removed and dismantled (2) Crosshead bearing, dismantled (3) Crank bearing and main bearing, dismantled (4) Cylinder liner in the installed condition (5) Cylinder head, valves disassembled (6) Control gear camshaft and crankcase with opened covers (7) Further components deemed necessary by the Society

Fig. 6.8-1 Power/Speed Diagram


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8.4.1 Notification and Announcement of Approval The Society will issue a certificate of approval specifying the approval number, date and conditions, etc. upon examination of the submitted documents and surveyor’s reports and make announcement the approval per the list published annually.

8.4.2 Modification of Approval Conditions When partial technical modifications which will affect the function and safety of an engine already approved, the Society may require tests and inspection concerned to the modifications.

8.4.3 Revocation of Approval In case where either of the following (1) to (3) applies, the Society will revoke the approval and give notice to the manufacturer. (1) Where the tests required in 8.4.2 is not conducted without any reasonable cause. (2) Where the result of the tests required in 8.4.2 is found inappropriate to continue the approval. (3) Where an applicant for revocation is made by the manufacturer. (4) Where the Society considers that the continuation of the approval is inappropriate.

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Chapter 9 APPROVAL OF USE OF MECHANICAL JOINTS

9.1 General

9.1.1 Scope The requirements of this chapter apply to testing and inspection for approval of use of mechanical joints on ships in accordance with the requirements of 12.3.3-1, Part D of Rules for the Survey and Construction of Steel Ships.

9.2 Application

9.2.1 Application Form The manufacturer, who intends to obtain the approval of use, is to submit an application (Specimen Form 6-9) filled in with necessary data and information to the Society (Head Office).

9.2.2 Documents 1 The documents listed (1) through (9) below, each in triplicate, are to be submitted together with the application form specified in 9.2.1. (1) Introduction of the manufacturing plant (2) Product quality assurance system implemented (3) Records of manufacture and delivery of the machinery and equipment (4) Complete description of the product (5) Typical sectional drawings with all dimensions necessary for evaluation of joint design (6) Complete specification of materials used for all components of the assembly (7) Approval test plan (the place of test and scheduled date of test are to be entered) (8) Test records (when preliminary test is carried out) (9) Others which are considered necessary by the Society 2 Notwithstanding the requirements in -1 above, submission of part or all of the reference may be omitted if the manufacturer had previous record of obtaining the approval of the Society in the past, and the duplicated data are included therein.

9.3 Approval Tests

9.3.1 General 1 Testing requirements for mechanical joints are to be as indicated in Table 6.9-1. Unless otherwise specified, the water or oil as test fluid is to be used. 2 Test specimens are to be selected from production line or at random from stock. Where there are various sizes from type of joints requiring approval, minimum of three separate sizes representative of the range, from each type of joints are to be subject to the tests listed in Table 6.9-1. 3 Where not specified, the length of pipes to be connected by means of the joint to be tested is to be at least five times the pipe diameter. In all cases the assembly of the joint is to be carried out only according to the manufacturer instructions. No adjustment operations on the joint assembly, other than that specified by the manufacturer, are permitted during the test. 4 Where a mechanical joint assembly does not pass all or any part of the tests in Table 6.9-1, two assemblies of the same size and type that failed are to be tested and only those tests which mechanical joint assembly failed in the first instance, are to be repeated. In the event where both of the assemblies pass the second test, that size and type of assembly is considered acceptable. 5 The methods and results of each test are to be recorded and reproduced as and when required.


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Table 6.9-1 Testing requirements for mechanical joints Tests Types of mechanical joints

Slip-on joints

Compression couplings and pipes unions

Grip type &machine grooved type

Slip type

1 Tightness test + + + 2 Vibration

(fatigue)test + + -

3 Pressure pulsation test(1)

+ + -

4 Burst pressure test

+ + +

5 Pull-out test + + - 6 Fire endurance

test(4) + + +

7 Vacuum test(5) +(3) + + 8 Repeated

assembly test +(2) + -

Notes : + : Test is required, - : Test is not required (1) For use in those systems where pressure pulsation other than water hammer is expected. (2) Except press type. (3) Except joints with metal-to-metal tightening surfaces. (4) If required approved fire resistant types by 12.3.3-1, Part D of Rules for the Survey and Construction of Steel

Ships. (5) For use in suction lines.

9.3.2 Details of Tests In the approval tests of mechanical joints, the following items (1) through (9) as deemed necessary by the Society are to be included according to Table 6.9-1 : (1) Tightness test

(a) Mechanical joint assembly test specimen is to be connected to the pipe or tubing, filled with test fluid and de-aerated. Mechanical joints assemblies intended for use in rigid connections of pipe lengths, are not to be longitudinally restrained. Pressure inside the joint assembly is to be slowly increased to 1.5 times of design pressure. This test pressure is to be retained for a minimum period of 5 minutes. The mechanical joint is to be examined visually for loss of pressure and sign of leakage during the test. Other alternative tightness test procedure, such as pneumatic test, may be accepted.

(b) For compression couplings a static gas pressure test is to be carried out to demonstrate the integrity of the mechanical joints assembly for tightness under the influence of gaseous media. The pressure is to be raised to maximum pressure or 7 MPa which ever is less. Where the tightness test is carried out using gaseous media as permitted in (a) above, then the static pressure test mentioned in (b) above need not be carried out.

(2) Vibration (fatigue)test (a) Testing of compression couplings and pipe unions

Compression couplings, pipe unions or other similar joints intended for use in rigid connections of pipe are to be tested in accordance with this method described as follows. Rigid connections are joints, connecting pipe length without free angular or axial movement. Two lengths of pipe is to be connected by means of the joint to be tested. One end of the pipe is to be rigidly fixed while the other end is to be fitted to the vibration rig. The test rig and the joint assembly specimen being tested is to be arranged as shown in Fig.6.9-1. The joint assembly is to be filled with test fluid, de-aerated and pressurised to the design pressure of the joint.

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Pressure during the test is to be monitored. The mechanical joint is to be examined visually for loss of pressure and sign of leakage during the test. Visual examination of the joint assembly is to be carried out for signs of damage which may eventually lead to joint leakage. Re-tightening may be accepted once during the first 1000 cycles. Vibration amplitude is to be within 5% of the value calculated from the following formula. Test specimen is to withstand not less than 107 cycles with frequency 20-50 Hz without leakage or damage.

EDSLA

32 2

=

A : single amplitude (mm) L : length of the pipe (mm) S : allowable bending stress based on 0.25 of the yield stress (N/mm2 ) E : modulus of elasticity of tube material (N/mm2) D : outside diameter of tube (mm)

Fig. 6.9-1 Vibration (fatigue) testing arrangement of compression couplings and pipe unions

(b) Slip-on Joints Slip-on Joints containing elastic elements, except slip type joints, are to be tested in accordance with the following method. A test rig of cantilever type used for testing fatigue strength of components may be used. The test specimen being tested is to be arranged in the test rig as shown in Fig. 6.9-2. Two lengths of pipes are to be connected by means of joint assembly specimen to be tested. One end of the pipe is to be rigidly fixed while the other end is to be fitted to the vibrating element on the rig. The length of pipe connected to the fixed end is to be kept as short as possible and in no case exceeds 200 mm. Mechanical joint assemblies are not to be longitudinally restrained. The assembly is to be filled with test fluid, de-aerated and pressurized to the design pressure of the joint. Preliminary angle of deflection of pipe axis is to be equal to the maximum angle of deflection, recommended by the manufacturer. The amplitude is to be measured at 1 m distance from the center line of the joint assembly at free pipe end connected to the rotating element of the rig. Parameters of testing are to be as indicated Table 6.9-2 and to be carried out on the same assembly. Pressure during the test is to be monitored. The mechanical joint is to be examined visually for loss of pressure and sign of leakage during the test. Visual examination of the joint assembly is to be carried out for signs of damage which may eventually cause leakage.


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Fig. 6.9-2 Vibration (fatigue) testing arrangement of slip-on joints

Table 6.9-2 Parameters of Vibration (fatigue) test for slip-on joints Number of cycles Amplitude, mm Frequency, Hz

3×106 ±0.06 100 3×106 ±0.5 45 3×106 ±1.5 10

(3) Pressure pulsation test

Joint assemblies intended for use in rigid connections of pipe lengths, are to be tested in accordance with the following method. The mechanical joint test specimen for carrying out this test may be the same as that used in the test in (1)(a) provided it passed that test. The vibration test in (2) above and the pressure pulsation test are to be carried out simultaneously for compression couplings and pipe unions. The mechanical joint test specimen is to be connected to a pressure source capable of generating pressure pulses of magnitude as shown in Fig 6.9-3. Impulse pressure is to be raised from 0 to 1.5 times the design pressure of the joint with a frequency equal to 30-100 cycles/minute. The number of cycles is not to be less than 5×105. The mechanical joint is to be examined visually for sign of leakage or damage during the test.

Fig. 6.9-3 Impulse pressure diagram

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(4) Burst pressure test

Mechanical joint test specimen is to be connected to the pipe or tubing in accordance with the requirements of 9.3.1-3, filled with test fluid, de-aerated and pressurized to test pressure of 4 times the design pressure with an increasing rate of 10%/ minute of test pressure. The mechanical joint assembly intended for use in rigid connections of pipe lengths is not to be longitudinally restrained. Duration of this test is not to be less than 5 minutes at the maximum pressure. Where consider convenient, the mechanical joint test specimen used in tightness test in (1) above, same specimen may be used for the burst test provided it passed the tightness test. The specimen may have small deformation whilst under test pressure, but no leakage or visible cracks are permitted. For design pressures above 20 MPa the required burst pressure will be specially considered by the Society.

(5) Pull-out test Pipe length of suitable size is to be fitted to each end of the mechanical joints assembly test specimen. The test specimen is to be pressurized to design pressure such that the axial loads imposed are of a value calculated by the following formula :

PDF 2

4π

=

D : pipe inside diameter (mm) P : design pressure (N/mm2) F : applied axial load (N)

This axial load is to be maintained for a period of 5 minutes. During the test, pressure is to be monitored and relative movement between the joint assembly and the pipe measured. The mechanical joint assembly is to be visually examined for drop in pressure and signs of leakage or damage. There are to be no movement between mechanical joint assembly and the connecting pipes.

(6) Fire endurance test Mechanical joint assembly test specimen is to be subject to fire for 30 min at a temperature of 800, while water at the design pressure of the joint is circulated inside. Specimen is to be completely engulfed in the flame envelope. The water temperature measured at the outlet of the test specimen is not to be less than 80 during the test. After the fire testing, the specimen is to be subjected to a hydrostatic tightness test as defined in (1)(a) above. As an alternative, the fire test may be conducted with circulating water at a pressure of at least 0.5 MPa and a subsequent pressure test to twice the design pressure. Pressure and temperature during the test is to be monitored. Where the mechanical joint is intended for use in systems conveying flammable fluids, there is to be no loss of pressure and visual examination should show no leakage. For services other than flammable fluids, leakage rate is not to be more than 0.2 l/min.

(7) Vacuum test Mechanical joint assembly is to be connected to a vacuum pump and subjected to a pressure 17 kPa absolute. Once this pressure is stabilized the mechanical joint assembly test specimen under test are to be isolated from the vacuum pump and this pressure is to be retained for a period of 5 minutes. Pressure is to be monitored during the test. No internal pressure rise is permitted.

(8) Repeated assembly test Mechanical joint test specimen are to be dismantled and reassembled 10 times in accordance with manufacturers instructions and then subjected to a tightness test as defined in (1) above.

(9) Other tests as deemed necessary by the Society

9.4 Approval

9.4.1 Test Records The manufacturer is to prepare records of the approval test after completion of the test, to obtain verification by the Society's attending surveyor and to submit them, in triplicate, to the Society.

9.4.2 Notification of Approval The Society, when satisfied upon examination of the submitted documents and the attending surveyor’s report,


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will issue a certificate of approval specifying the approval number, approval date, items of approval and approval conditions, put approval stamps on the documents as deemed necessary by the Society out of those submitted in accordance with 9.2 and 9.4.1, and return them back to the applicant.

9.4.3 Renewal of Approval 1 The valid term of approval in the preceding 9.4.2 will be 5 years. 2 In case where renewal of validity is intended, the manufacturer is to submit the existing certificate in accordance with the requirements of 9.2 newly. In this case, the data required per 9.2 may be limited to the portion subjected to modification only. 3 When approval has been granted to an application with partial changes in the content of approval, the Society may require additional tests for approval.

9.4.4 Revocation of Approval In case where either of the following (1) through (4) applies, the Society will revoke the type approval of machinery and equipment, and give notice to the manufacturer. (1) In association with the implementation or revision of international conventions, laws, and regulations, the

equipment for which the approval was granted do not deserve the approval any longer. (2) In case where the validity of approval is overdue and no application for the renewal of the approval is submitted. (3) When serious shortcomings are found in structure or quality of the equipment already approved after being


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Form 6-9


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Chapter 10 APPROVAL OF USE OF CRANKCASE EXPLOSION RELIEF VALVES

10.1 General

10.1.1 Scope The requirements in this Chapter apply to testing and inspection for approval of use of crankcase explosion relief

valves in accordance with the requirements of 2.4.3 Part D of the Rules for the Survey and Construction of Steel Ships.

10.2 Application

10.2.1 Application Form The manufacturer, who intends to obtain the approval of use, is to submit an application (Specimen Form 6-10)

filled in with necessary data and information to the Society (Head office).

10.2.2 Documents The documents listed (1) through (7) below, each in triplicate, are to be submitted together with the application

form specified in 10.2.1. (1) Specifications (2) Construction drawings and summary of working principles (3) Approval test plan (the place of test and scheduled date of test are to be entered) (4) Data on the summary of test facilities (5) Information on the manufacturing and quality control standards (6) Records of manufacture and delivery (7) Others which are considered necessary by the Society

10.3 Approval Tests

10.3.1 General 1 Crankcase explosion relief valves are to be tested in accordance with 10.3.2. 2 Test facilities for carrying out of testing of the valves are to comply with the followings: (1) The test facilities where testing is carried out are to be accredited to a national or international standard for the

testing of explosion protection devices and be acceptable to the Society. (2) The test facilities are to have equipment for controlling and measuring a methane gas in air concentration within

a test vessel to an accuracy of ±0.1%. The test vessel is to have connections for measuring the methane in air mixture in at least two positions (top and bottom).

(3) The test vessel for explosion testing is to be provided a means of fitting an ignition source at a position approximately one third the height or length of the vessel opposite to where the valve is mounted.

(4) The test vessel is to be provided with the pressure measuring equipment in at least two positions (one at the valve and the other at the test vessel centre). The measuring arrangements are to be capable of measuring and recording the pressure changes throughout an explosion test.

(5) The height or length between dished ends of the test vessel is to be approximately 2 times its diameter but not more than 2.5 times.

(6) The test vessel is to be provided with a flange for mounting the explosion relief valve in an orientation consistent with how it will be installed in service (in the vertical plane or the horizontal plane). The flange arrangement is to be made approximately one third of the height or length of the test vessel.

(7) A circular plate to provide simulation of the crankcase surface is to be provided for fitting between the pressure vessel flange and valve to be tested. The circular plate is to have the following dimension.

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(a) Outside diameter: Two times of the outer diameter of the valve top cover (b) Internal bore: The same internal diameter of the valve

(8) The free area of the explosion relief valve is to be not less than 115 cm2 per 1 m3 of crankcase gross volume. In any case the volume of the test vessel is not to vary by more than +15% to -10% from the 115 cm2/m3 volume ratio. The internal volume of the test vessel is to be determined from the vessel dimensions that include any standpipe arrangements.

10.3.2 Details of Tests 1 Three valves of each size are to be tested for each orientation that they are intended to be installed on the engine and test specimens are to be selected from the manufacturer's usual production line. The valves are to have been tested at the manufacturer's works to demonstrate that the opening pressure is 0.005±0.001 MPa and that the valve is air tight at a pressure below the opening pressure for at least 30 seconds. 2 All explosion tests to verify the functionality of the valves are to be carried out using an air and methane mixture with a methane concentration of 9.5±0.5%. The concentration of methane in the test vessel is to be measured in the top and bottom of the vessel and is not to differ by more than 0.5%. 3 The pressure in the test vessel is to be not less than atmospheric and not exceed 0.02 MPa. 4 The ignition is to be made using a 100 joule explosive charge. 5 Where valves are to be installed on an engine with shielding arrangements to deflect the emission of explosion combustion products, the valves are to be tested with the shielding arrangements fitted. 6 Successive explosion testing to establish a valve's functionality is to be carried out during stable weather conditions by the following procedures. (1) Stage 1:

Two explosion tests are to be carried out with the flange opening fitted with the circular plate covered by a 0.05 mm thick polythene film.

(2) Stage 2: Two explosion tests are to be carried out on three different valves of the same size by the following procedures. Each valve is to be mounted in the orientation that it requires approval for installation with the circular plate described in 10.3.1-2(7) located between the valve and pressure vessel mounting flange. (a) The first of the two tests on each valve is to be carried out with a 0.05 mm thick polythene bag having a

minimum diameter of three times the diameter of the circular plate and volume not less than 30% of the test vessel enclosing the valve and circular plate. Before carrying out the explosion test the polythene bag is to be empty of air. Provided that the first explosion test demonstrated that there was indication of combustion outside the flame arrester and there are sign of damage to the flame arrester or valve, the test is unsatisfactory and the following test is not carried out.

(b) A second explosion test is to be carried out without the polythene bag arrangement. During the second explosion test, it is to be verified that there was no indication of combustion outside the flame arrester and there are no sign of damage to the flame arrester or valve.

(3) Stage 3: Carry out two further explosion tests as described in Stage 1.

7 The pressure rise and decay during an explosion is to be recorded with indication of the pressure variation showing the maximum overpressure and steady under pressure in the test vessel during testing. The pressure variation is to be recorded at two points in the pressure vessel. The concentration of methane in the test vessel is to be measured before testing. 8 The effect of the valve in terms of pressure rise following an explosion is ascertained from maximum pressures recorded at the centre of the test vessel during the three stages of the preceding -6. The pressure rise within the test vessel due to the installation of an explosion relief valve is the difference between average pressure of the four explosions from stage 1 and 3 and the average of the first tests on the three valves in stage 2. 9 The valve tightness is to be ascertained by verifying from records that an under pressure of at least 0.03 MPa is held by the test vessel for at least 10 seconds following an explosion of the preceding -6(2)(a) and (b). The tightness of the valve may be verified by the separate test after the explosion test of the preceding -6(2)(b). 10 After completing the explosion tests, the valves are to be dismantled and the condition of all components ascertained and documented. In particular any indication of valve sticking or uneven opening is to be noted.


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Photographic records of the valve condition are to be taken and included in the report. 11 The result of each test is to be documented by video recording. The video recording is to be retained by manufacturer.

10.3.3 Witness of Tests For cases where test samples are identified or where the approval test is carried out, they are, in principle, at the

presence of the Society's surveyor.

10.3.4 Test Records The manufacturer is to prepare records of the approval test including the following information and documents

after completion of the test, to obtain verification by the Society's attending surveyor and to submit them, in triplicate, to the Society. (1) Test specification (2) Details of test pressure vessel and valve tested (including the test vessel volume, the valve free area and of the

flame arrester and valve lift at 0.02 MPa) (3) The orientation in which the valve was tested (vertical or horizontal position) (4) Methane in air concentration for each test (5) Ignition source (6) Pressure curves for each test

10.4 Approval

10.4.1 Notification of Approval The Society, when satisfied upon examination of the submitted documents as required per 10.2 and 10.3 and the

attending surveyor's report, will issue a certificate of approval specifying the approval number, approval date, items of approval and approval conditions, put approval stamps on the documents as deemed necessary by the Society out of those submitted in accordance with 10.2.2 and 10.3.4, and return them back to the applicant.


10.4.3 Revocation of Approval In case where either of the following (1) through (4) applies, the Society will revoke the type approval of

machinery and equipment, and give notice to the manufacturer. (1) In association with the implementation or revision of international conventions, laws, and regulations, the



10.5 Marking

Manufacturers are to mark the product before shipment for identification of approval equipment and, in addition, at least the following items are to be marked at the suitable place. (1) Names and address of manufacturer (2) Designation and size (3) Month/Year of manufacture (4) Approved installation orientation

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Form 6-10 APPLICATION FOR APPROVAL OF USE OF CRANKCASE EXPLOSION RELIEF VALVES

( Initial, Renewal, Modification)

To: Machinery Department, NIPPON KAIJI KYOKAI 4-7, Kioi-cho, Chiyoda-ku, Tokyo 102-8567, JAPAN Ref. No.: Date:

Name of Applicant:

Address:

Phone No./Fax. No.:

Name of the Person in Charge: We hereby apply for type approval of the following valve in accordance with the requirements of Chapter 10, Part 6 of the Guidance for the Approval of Materials and Equipment for Marine Use of Nippon Kaiji Kyokai.

Names/Types of valve

Type approval Nos. If Available

Particulars

Names of Manufacturer and Production Site

Address of Manufacturer

Drawings

Drawings and Documents Attached Documents

Date of Tests/Inspections and Places

Notes: 1. Use additional sheets if necessary. 2. Tick off where appropriate


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Part 7 CONTROL AND INSTRUMENTATION EQUIPMENT AND ELECTRICAL INSTALLATIONS

Chapter 1 APPROVAL OF USE OF AUTOMATIC DEVICES AND EQUIPMENT

1.1 General

1.1.1 Scope The requirements in this chapter apply to tests and inspection for the approval to exempt the shop tests partially or entirely for automatic devices and equipment (hereinafter referred to as “the equipment” in this chapter) intended to be installed in ship in accordance with 18.7.2, Part D of the Rules for the Survey and Construction of Steel Ships.


1.2.1 Application Procedures The manufacturer (applicant) of the equipment intended to be applied the requirements in this chapter is to submit an application (Form 7-1) accompanied with three copies each of the following drawings and documents to the Society. (1) Specifications (description of the product name, type, principal particulars, use, construction, performance, etc.) (2) List of equipment including the similar type (3) System diagram (when systems are composed of plural units) (4) Construction drawings (general dimensions and sectional assembly plan, etc.) (5) Wiring diagram (electrical systems), piping diagram (pneumatic or hydraulic systems) (6) List of major parts (this may be included in the above (2) or (4))

Note : 1. Product name, principal particulars, material, quantity, applicable rules and standards are to be specified. 2. Bought-in parts are to be included.

(7) Instruction manual (including operating procedure) (8) Inspection and test specification for quality control (including test data) (9) Past records of products (10) Environmental test procedures prepared according to 1.3. (11) Certificate and test result certificate issued by bodies recognized by the Society (if any)

1.3 Environmental Test

1.3.1 Approval Test (1) After the drawings and documents submitted in accordance with 1.2.1 have been examined, tests are to be

carried out in accordance with the testing condition and method of Table 7.1-1 in the presence of the Society’s surveyor, and they are to be proven to satisfy the criteria of Table 7.1-1.

(2) Where tests which do not fully comply with the testing condition and methods, and the criteria of Table7.1-1, they may comply with a standard deemed appropriate by the Society such as IEC 60092-504 (Electrical installations in ships - Special features，Control and instrumentation，Section 3: Environmental and supply conditions and testing)，IEC 60945 (Maritime Navigation and Radiocommunication Equipment and Systems - General Requirements - Methods of Testing and Required Test Results)，IEC 60533 (Electrical and electronic installations in ships - Electromagnetic compatibility)，JIS F 0807 (General Rules for Environmental Tests of

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Control and Instrumentation Equipment for Marine Use). (3) In case the documents in 1.2.1(11) are deemed appropriate, a part of tests may be exempted. (4) Tests are to be carried out under normal temperature (25± 10), normal humidity (60%± 30%), normal

atmospheric pressure (96 kPa± 10 kPa), rated electrical source voltage and rated electrical source frequency unless otherwise specified. The number of test sample is, as a rule, to be one for each type. However, additional test sample may be required when deemed necessary by the Society.

Table7.1-1(a) Environmental Test Items, Testing Conditions, Methods, and Criteria

Test Item Testing condition and method Criteria

External examination

- Examine the external, structure, etc., of the equipment - They comply with the specifications.

Operation test and performance test

- Check the operation of the equipment. - Check the self monitoring features if provided.

- The equipment operates satisfactory.

Electrical power supply failure test

- Check the operation of the equipment when the external electrical power supply is interrupted 3 times during 5 minutes. (interruption time is 30 seconds each time)

- No abnormality is observed on loss and restoration of the electrical power supply. -No corruption of program or data is observed, where applicable.

Electrical power supply fluctuation

test

- Check the operation of the equipment when the external electrical power supply varies as shown in the following (Note: Numerical values signify percentages for the rated value)

- No abnormality is observed. - The equipment operates satisfactory. - No corruption of programme or data is observed, where applicable.

Fluctuation

a.c. permanent Voltage Frequency

Combination 1 Combination 2 Combination 3 Combination 4

+6 +6 -10 -10

+5 -5 +5 -5

a.c. transient Voltage 1.5 sec.

Frequency 5 sec.

Combination 5 Combination 6

+20 -20

+10 -10

d.c. Voltage

For the equipment not related to a battery

Voltage tolerance (continuous)

± 10

Voltage cyclic variation

5

Voltage ripple 10

For the equipment related to a battery

For the equipment connected to a battery during charging

-25，+30

For the equipment not connected to a battery during charging

-25，+20

Power supply fluctuation test

- Check the operation of the equipment when the pneumatic and the hydraulic power supplies are maintained continuously +20% and -20% of the working pressure for at least 15 minutes.

- No abnormality is observed. - The equipment operates satisfactory.


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Table7.1-1(b) Environmental Test Items, Testing Conditions, Methods, and Criteria Test Item Testing condition and method Criteria

Insulation resistance test

- Measure the insulation resistance between current carrying parts and between current parts and earth when measured with the following application voltage.

- The insulation resistance (MΩ) is not less than the value specified in the following.

Rated voltage: Vr(V) Test voltage (V) Rated voltage

Before test After test

Vr≤ 65 Vr＞65

2×Vr, min.24 500

Vr≤ 65 Vr＞65

10 100

1 10

- Measurements are carried out before and after damp heat test, cold test, salt mist test and High voltage test. - For the equipment containing circuits in which electronic apparatus are used and the application of the test voltage is not desirable, the test voltage is applied after removing the circuits.

High voltage test

- Apply the following test voltage, alternating of a frequency of 50 Hz or 60 Hz, between current carrying parts and between current-carrying parts connected and earth for 1 minute.

- No abnormality is observed.

Rated voltage: Vr(V) Test voltage (V)

Vr≤ 65 65＜Vr≤ 250 250＜Vr≤ 500 500＜Vr ≤ 690

2× Vr+500 1500 2000 2500

- For the equipment containing circuits in which electronic apparatus are used and the application of the test voltage is not desirable, the test voltage is applied after removing the circuits.

Pressure test - Apply the pneumatic or hydraulic pressure of 1.5 times the designed pressure.

- No abnormality is observed.

Dry heat test - The equipment is at an operating condition and apply the environmental condition of +70± 2 for 2 hours. And check the operation of the equipment during the last hour at the test temperature and after recovery. - For the equipment except ones installed in consoles, housing etc. together with other equipment, the environmental condition of +55± 2 for 16 hours may be applied. - Detailed test methods are referred to IEC 60068-2-2.


Damp heat test - Apply two cycles of the environmental condition of temperature of +55± 2 and relative humidity of 90%± 5% for 24 hours every one cycle. (The condition is to be applied during the first 12 hours, and removed during the last 12 hours.) The equipment is operating condition during complete first cycle and switched off during second cycle except for the operation test. And check the operation of the equipment during the first 12 hours of the first cycle at the environmental condition, during the last 12 hours of the second cycle at the environmental condition and after recovery. - Detailed test methods are referred to Test Db of IEC 60068-2-30.


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Table7.1-1(c) Environmental Test Items, Testing Conditions, Methods, and Criteria Test Item Testing condition and method Criteria

Vibration test - The equipment is at an operating condition and apply the sweeping of vibration specified in the following over the frequency range of 2(+3，-0) Hz-100 Hz in order to find resonance points. (points of which amplification factor : Q≤ 2 are considered resonance points.)


Frequency Amplitude or Acceleration

2(+3，-0) Hz-13.2 Hz Amp. ± 1.0 mm 13.2 Hz - 100 Hz Acceleration ± 0.7 g

- When resonance points do not exist, apply the vibration of acceleration ± 0.7 g at 30 Hz for 90 minutes as an endurance test. - When resonance points exist, repeat the test with necessary provisions to avoid resonance or apply the vibration (same amplitude or acceleration of resonance point) at the resonance frequency for 90 minutes as an endurance test. In case of several resonance points are found close to each other, the sweeping of vibration for 120 minutes as a sweeping endurance test may be applied. - Check the operation of the equipment during the endurance test. - The test is carried out in three axis direction. - For the equipment intended to be installed in severe vibration conditions such as diesel engines, air compressors, the vibration level specified in the following is applied.

Frequency Amplitude or Acceleration

２(+3，-0) Hz-25.0 Hz Amp. ± 1.6 mm 25.0 Hz-100 Hz Acceleration ± 4.0 g - Detailed test methods are referred to Test Fc of IEC 60068-2-6.

Inclination test - The equipment is at an operating condition and check the operation of the equipment with 22.5°static inclination. - The equipment is at an operating condition and check the operation of the equipment with rolling of 22.5°at period of about 10 seconds. - The test is carried out at athwartships and bow-and-stern inclinations. - On ships for the carriage of liquefied gases and chemicals, the emergency power supply is to remain operational with the ship flooded up to a maximum final athwartships inclination of 30°.


Cold test - The equipment is switched off except for the operation test and apply the environmental condition of +5 ± 3 for 2 hours. And check the operation of the equipment during the last hour at the test temperature and after recovery. - For the equipment installed in open decks, etc., the environmental condition of -25± 3 is applied. - Detailed test methods are referred to Test Ab or Test Ad of IEC 60068-2-1.


Salt mist test - The equipment is switched off except when its operation is checked. Apply four cycles of the environmental condition of spraying NaCl liquid for 2 hours and leaving for 7 days. Check the operation of the equipment during the 7th day of each cycle and 4 to 6 hours after recovery. - Detailed test methods are referred to Test Kb of IEC 60068-2-52.



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Table7.1-1(d) Environmental Test Items, Testing Conditions, Methods, and Criteria Test Item Testing condition and method Criteria

Electrostatic discharge

immunity test

- Check the operation of the equipment when the electrostatic discharge immunity test is carried out according to the following condition.

- Performance Criterion B(*2)

Contact discharge 6 kV

Air discharge 8 kV

Interval between single discharges

1 sec.

No. of Pulses 10 per polarity

- Detailed test methods are referred to Level 3 of IEC 61000-4-2.

Radiated radio frequency

immunity test

- Check the operation of the equipment when the radiated radio frequency immunity test is carried out according to the following condition.

- Performance Criterion A(*1)

Frequency range 80 MHz - 2 GHz

Modulation 80% AM at 1 kHz

Field strength 10 V/m

Frequency sweep rate ≤ 1.5×10-3decades/sec. (or 1% / 3sec.)

- If for tests of equipment an input signal with a modulation frequency of 1 kHz is necessary a modulation frequency of 400 Hz may be chosen. - Detailed test methods are referred to Level 3 of IEC 61000-4-3.

Conducted low frequency

immunity test

- Check the operation of the equipment when the conducted low frequency immunity test is carried out according to the following condition. (values in round brackets are shown where the rated frequency of the equipment is 50 Hz)


Frequency range 60 Hz - 12 kHz (50 Hz - 10 kHz)

Test voltage AC 10% of supply voltage

60 Hz - 900 Hz (50 Hz - 750 Hz)

10 to 1％ of supply voltage

900 Hz - 6 kHz (750 Hz - 5 kHz)

10% of supply voltage

6 kHz - 12 kHz (5 kHz - 10 kHz)

DC 10% of supply voltage

50 Hz - 10 kHz

Maximum power 2 W - Detailed test methods are referred to IEC 60533.

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Table7.1-1(e) Environmental Test Items, Testing Conditions, Methods, and Criteria Test Item Testing condition and method Criteria

Conducted high frequency

immunity test

- Check the operation of the equipment when the conducted high frequency immunity test is carried out according to the following condition.


Frequency range ≤ 150 kHz - 80 MHz

Modulation 80% AM at 1 kHz

Amplitude 3 V rms

Frequency sweep range 1.5×10-3decades/sec. (or 1% / 3sec.)

- This test is to be applied to AC, DC, I/O ports and signal/control lines. - If for tests of equipment an input signal with a modulation frequency of 1 kHz is necessary a modulation frequency of 400 Hz may be chosen. - For equipment installed in the bridge and deck zone, the following test levels are to be added.

Spot frequencies 2,3,4,6.2,8.2,12.6,16.5,18.8,22,25 MHz

Amplitude 10 V rms

- Detailed test methods are referred to Level 2 of IEC 61000-4-6. Burst/Fast transient

immunity test

- Check the operation of the equipment when the burst/fast transient immunity test is carried out according to the following condition.


Single pulse time 5 nS (between 10% and 90% value) Single pulse width 50 nS (50% value)

Amplitude line on power supply port/earth: 2 kV line on I/O data control and

communication ports (coupling clamp): 1 kV

Pulse period 300 mS Burst duration 15 mS

Duration 5 min./polarity - Detailed test methods are referred to Level 3 of IEC 61000-4-4.

Surge immunity test

- Check the operation of the equipment when the surge immunity test is carried out according to the following condition.


Pulse rise time 1.2 μS (between 10% and 90% value)

Single pulse width 50 μS (50% value)

Amplitude line/earth: 0.5, and 1 kV

line/line: 0.5 kV

Reputation rate at least 1 pulse/min.

No. of pulses 5 per polarity - Test procedure is to be in accordance with Fig. 7.1-1 where power and

signal lines are identical. - Detailed test methods are referred to Level 2 of IEC 61000-4-5.


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Table7.1-1(f) Environmental Test Items, Testing Conditions, Methods, and Criteria Test Item Testing condition and method Criteria

Radiated emission test

- Radiated emission test is to be carried out according to the following. - Radiated emission is to be within limits in the table.

- For equipment installed in the bridge and deck zone.

Frequency range Limits (dBμV/m) 150 kHz - 300 kHz 80 - 52 300 kHz - 30 MHz 52 - 34 30 MHz - 156 MHz 54 156 MHz - 165 MHz 24 165 MHz - 2 GHz 54

- For equipment other than the above. Frequency range Limits (dBμV/m)

150 kHz - 30 MHz 80 - 50 30 MHz - 100 MHz 60 - 54 100 MHz - 156 MHz 54 156 MHz - 165 MHz 24 165 MHz - 2 GHz 54

- Distance between equipment and antenna is to be 3 m. - Detailed test methods are referred to CISPR 16-1,16-2.

Conducted emission test

- Conducted emission test is to be carried out according to the following. - Conducted emission is to be within limits in the table.

- For equipment installed in the bridge and deck zone.

Frequency range Limits (dBμV) 10 kHz - 150 kHz

150 kHz - 350 kHz 350 kHz - 30 MHz

96 - 50 60 - 50

50

- For equipment other than the above. Frequency range Limits (dBμV)

10 kHz - 150 kHz 120 - 69 150 kHz - 500 kHz 79 500 kHz - 30 MHz 73 - Detailed test methods are referred to CISPR 16-1,16-2.

Remarks: (＊1) Performance Criterion A: The Equipment Under Test (EUT) is to continue to operate as intended during and after the

tests. No degradation of performance or loss of function is allowed as defined in relevant equipment standard and the technical specification published by the manufacturer.

(＊2) Performance Criterion B: The EUT is to continue to operate as intended after the test. No degradation of performance or loss of function is allowed as defined in the technical specification published by the manufacturer. During the test, degradation or less of function or performance which is self recoverable is however allowed but no change of actual operating state or stored data is allowed.

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Fig. 7.1-1 Example of Surge Immunity Test Circuits

1.4 Approval Procedures

1.4.1 Test Records Manufacturer is to submit promptly three copies of the test records to the Society after completion of the tests.

1.4.2 Certificate When the results of the tests specified in 1.3.1 are confirmed appropriate, the Society approves the equipment and issues certificate specifically provided for.

1.4.3 Term of Validity The above certificate is valid for 6 years.

1.4.4 Renewal of Validity For renewal the validity, manufacturer is to submit to the Society an application (Form 7-1, attached) accompanied with the certificate previously issued. The change of the specification, if any, is to be described in the application. When the specifications of the approved equipment remain unchanged, the certificate will be issued with another 6 years valid term by the Society.


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1.5 Changes in Particulars, Material, Construction, etc. of Approved Equipment

1.5.1 Changes in Particulars, Material, Construction, etc. of Approved Equipment 1 In case where the particulars, materials, construction, dimensions, etc. of major components of the approved equipment are intended to be changed, the manufacturer is to submit to the Society each three copies of application for changes (Form 7-1, attached), explanatory notes for changes and necessary drawings, accompanied with the certificate previously issued. 2 Upon examination of the drawings and documents, etc. according to 1.5.1 above, a confirmation test for changes are to be carried out when considered necessary.

The test items of confirmation tests are to be determined in each case according to the substance of changes. 3 When confirmation tests are carried out, the manufacturer is to submit to the Society three copies of the test records. 4 As a result of the examination of the application and confirmation test records, the Society, when deemed them appropriate, reissues the certificate with contents duly revised.


1.6.1 Revocation of Approval 1 In case where the approved equipment is considered relevant to either of the following, the approval may be revoked : (1) Where the result of the confirmation tests were found unsatisfactory. (2) Where the valid term of the certificate has expired. (3) Where withdrawal of the approval has been offered by the manufacturer. (4) Where the Society judged the approved equipment to be unsuitable in the light of the service records of the

shipboard automation equipment. 2 The manufacturer who received a notice of revocation of the approval should return the certificate of the relevant equipment to the Society.

1.7 Markings

1.7.1 Markings Manufacturers of the approved equipment are, in principle, to mark the product before shipment for identification of approved equipment and, in addition, at least the following items to be marked at the suitable place : (1) Manufacturer’s name or equivalent (2) Type No. or symbol (3) Serial No. and date of manufacture (4) Particulars or ratings

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Form 7-1

Note :

1. In case space is in short, use separate sheets. 2. Cross out with a straight line on unnecessary letter. 3. The applicant is to be identical to the section of the manufacturer in charge of the equipment concerned.


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Chapter 2 APPROVAL OF USE OF LOADING COMPUTER

2.1 General

2.1.1 Application The requirements in this chapter apply to tests for loading computers required to be installed in accordance with the requirements of 34.1.1, Part C of the Rules for the Survey and Construction of Steel Ships and stability computers applied the provisions of 1.3.1-1 of Annex U1.2.2 “GUIDANCE FOR STABILITY COMPUTER”.


Any manufacturer (applicant) of the loading computers and stability computers, intended to be applied the requirements in this chapter, is to submit an application (Specimen Form7-2) accompanied with three copies each of the following drawings and documents to the Society: (1) Specifications (description of the product name, type, principal particulars, use, purpose, construction,

performance, etc.) (2) Manual for construction, function and operating procedure (handling or operating procedure) (3) Inspection and test specification for quality control (including past data) (4) Records of manufacture and delivery (5) Environmental test plan (prepared according to 2.4.1) (6) Other data deemed necessary by the Society

2.3 Structural Requirements

Loading computers and stability computers are to have sufficient durability in the following environmental conditions, and to be capable of being operated without abnormalities. Special consideration is to be given to humidity.

It is recommended that a selfmonitoring features be contained within each loading computers and stability computers assembly to prevent computing errors due to failures of the circuits. (1) Ambient temperature

0 to 45 (2) Vibration

Amplitude: ±1.0 mm at 302+

− Hz to 13.2 Hz

Acceleration: ±0.7 g at 13.2 Hz to 100 Hz The vibrations during operation is to range from 2 Hz to 100 Hz with an acceleration of ±0.05 g.

(3) Inclination Longitudinal direction 10 degrees Transverse direction 15 degrees

(4) Power supply fluctuation (see Table 7.2-1)

Table 7.2-1 Power Supply Fluctuation Steadystate value Instantaneous value

A.C. power supply Voltage (rated) ±10% ±20% 1.5sec.

Frequency (rated) ±5% ±10% 3 sec.

D.C. power supply Voltage (rated) Fed during

charging +30%,-25%

Not fed during charging +20%,-25%

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2.4 Tests and Inspection

2.4.1 Environmental Tests Environmental tests for loading computers and stability computers are to be carried out, in the presence of the surveyor, in accordance with the test conditions and testing procedures specified in Table 7.2-2, and it is to be confirmed if they pass the acceptance criteria. Except where otherwise specified, tests are to be carried out as normal room temperature (25±10), normal room humidity (60%±30%), normal atmospheric pressure (96 kPa±10 kPa), the rated power supply voltage and the rated power supply frequency.

For loading computers and stability computers considered to be of the same basic type of those already approved by the Society, part or whole of these environmental tests may be omitted.

2.4.2 Certificates When the results of tests specified in 2.4.1 are confirmed appropriate, the Society approves the equipment and issues certificate specifically provided for.

2.4.3 Terms of Validity The above certificate is valid for four years.

2.4.4 Renewal of Validity For renewal of validity, the manufacturer is to submit to the Society an application (Specimen Form 7-2, attached) accompanied with the certificate previously issued. The change of the specification, if any, is to be described in the application. Where the specifications of the approved equipment remain unchanged, the certificate will be issued with another four years valid term by the Society.


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Table 7.2-2(a) Environmental Test Items, Testing Conditions and Methods, and Criteria

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Table 7.2-2(b) Environmental Test Items, Testing Conditions and Methods, and Criteria (cont’d)

2.5 Changes in Particulars, Material, Construction, etc. of Approved Equipment

2.5.1 Changes in Particulars, Material, Construction, etc. of Approved Equipment 1 In case where the particulars, materials, construction, dimensions, etc. of majour components of the approved equipment are intended to be changed, the manufacturer is to be submit to the Society each three copies of application for changes (Form 7-2, attached), explanatory notes for changes and necessary drawings, accompanied


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with the certificate previously issued. 2 Upon examination of the drawings and documents, etc. according to –1. above, a confirmation test for changes are to be carried out when considered necessary. 3 In case the results of confirmation tests specified in –2. are deemed appropriate, a new certificate will be issued by the Society. In this case, the previously issued certificate is to be returned to the Society.

2.6 Invalidation of Approved Products

2.6.1 Invalidation of Approved Products 1 In case either of the following is relevant, approval of the product will be invalidated: (1) Where the result of the confirmation tests were found unsatisfactory. (2) Where the valid term of the certificate has expired. (3) Where withdrawal of the approval has been offered by the manufacturer. (4) Where the Society judged the approved equipment to be unsuitable in the light of the service records. 2 Any manufacturer who has received notice of revocation of approval should return the certificate of the relevant equipment to the Society.

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Form 7-2

Note:

1. If there is insufficient space, use additional sheets. 2. Mark × in where appropriate,


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Chapter 3 APPROVAL OF CABLE LAYING

3.1 General

The requirements in this chapter apply to tests and inspection for the approval of fire stop method for bunched cables (including fire stop paints) herein after referred a “fire stop methods” in this chapter and non-metallic cable supports which are required an advance approval by the Society in accordance with 2.9.11-1 and 2.9.14-3(4)(a), Part H of the Rules for the Survey and Construction of Steel Ships.


3.2.1 Application The manufacturer or constructor intended to obtain the approval in accordance with the requirements in this chapter is to submit the application (Form 7-3) to the Society (Head Office).

3.2.2 Documents for Submission The manufacturer or constructor intended to obtain the approval of the fire stop methods is to submit three copies each of drawings and documents specified in (1) for the approval of the fire stop methods, and similarly those specified in (2) for the approval of non-metallic cable supports, together with the application specified in 3.2.1. (1) For fire stop methods

(a) Specification (including detailed construction plan) (b) Characteristic of materials (c) Instructions for work procedures (in case of paints being used, the painting method and procedure including

painting condition and the thickness of dry paint film are to be specified) (d) Approval test plan (see 3.4.1) (e) Copies of certificates or test records issued by official organizations (if any) (f) Other documents as deemed necessary by the Society.

(2) For non-metallic cable supports (a) Type name (b) Construction plan (including principal dimensions) (c) Characteristic of materials (d) Approval test plan (see 3.4.2) (e) Copies of certificates or test records issued by official organizations (if any) (f) Other documents as deemed necessary by the Society.


3.3.1 Approval of Test Plan Where the plan of the approval test submitted according to 3.2.2 is examined and considered acceptable, the Society will approve and return it back to the applicant. In case where the Society considered appropriate part of the approval test items may be omitted.

3.3.2 Confirmation of Manufacturing and Quality Control Procedures The Society, when it considers necessary on the basis of the data submitted according to 3.2.2, the confirmation survey on the manufacturing plant or the construction works may be carried out.

3.4 Approval Test

3.4.1 Approval Test of Fire Stop Methods The test is to be conducted in accordance with the standards deemed appropriate by the Society.

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3.4.2 Approval Test of Non-Metallic Cable Supports The test is to include any of the following items which the Society considers necessary, depending upon the purpose and kind of the non-metallic cable supports. (1) flame-retardant test in accordance with H2.5.3-1, Part H of the Guidance for the Survey and Construction of

Steel Ships (2) smoke and toxicity test based upon Part 2, Annex 1 of the International Code for Application of Fire Test

Procedures (3) safe working load test based upon 2.2 of the IACS Recommendation No.73 (4) impact resistance test based upon IEC 60068-2-75 (5) electrical conductivity test based upon IEC 60093

3.4.3 Witness of Test For cases where test samples are identified or where the approval test is carried out, they are, in principle, at the presence of the Society’s surveyor.

3.4.4 Test Records 1 After the approval test has been completed, the manufacturer or constructor is to prepare the approval test records and to submit three copies of them to the Society after being verified by the Society’s surveyor. 2 The record of the quality control conducted during the manufacturing process of the test samples for the approval test is to be submitted together with the approval test records in the preceding -1.

3.5 Approval

3.5.1 Approval Notice and Publicity 1 The Society, when satisfied upon examination of the submitted documents as required per 3.2 to 3.4 and the report of the attending surveyor, will approve the fire stop methods or non-metallic cable supports and issue an approval notice stating the approval number, date of approval, particulars and conditions, etc., and return the documents submitted under the requirements of 3.2.2 and 3.4.4 back to the applicant by putting approval stamp on some of them. 2 The Society will make public the approval by the list published annually.

3.5.2 Term of Validity The term of validity of the approval is to be four years counting from the day of approval.

3.5.3 Renewal of Approval 1 The manufacturer or constructor intended to have renewal of approval for the fire stop methods or non-metallic cable supports which have the expiration of term of validity or the modification in approved content, is to submit an application in accordance with the requirements in 3.2. In this case, the documents required in 3.2.2 may be limited to the portion subjected to the modification only. 2 In case where approval is given for the partial modification in the contents of approval, expiration date will not, in principle, be renewed.

3.5.4 Revocation of Approval In case the approval corresponds to any of the following items from (1) to (3), the Society may revoke the approval of the fire stop methods or non-metallic cable supports, and give a notice to the manufacturer or constructor concerned. (1) In case the fire stop methods or non-metallic cable supports previously approved becomes to be unable to

conform to the newly established requirements of international conventions, laws or rules (2) In case where serious troubles are caused by the construction and quality of the approved fire stop methods or

non-metallic cable supports after being applied ships (3) In case where an application for withdraw is made by the manufacturer or constructor


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Form 7-3

Note:

1. One copy of this application is to be submitted. 2. Delete ∗ as appropriate. 3. Tick in the “” as appropriate.

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Chapter 4 APPROVAL OF USE OF LEVEL INDICATORS

4.1 General

4.1.1 Scope 1 In accordance with the requirements in 13.8.4 and 14.2.8, Part D, and 4.2.2(3)(e)(iii), Part R of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”) and in N13.2.1(1) and S13.1.1-5 of the Guidance for the Survey and Construction of Steel Ships, the requirements in this chapter apply to tests and inspection for the approval for use in ships of level indicators installed in tanks, cofferdams, etc. 2 The electrical devices used for level indicators are to be specified in accordance with the requirements in Chapter 5, Part 8 as necessary.

4.1.2 Definition The level indicator includes all parts of the device from the detector to the display.

4.2 Application

4.2.1 Application Form The company, who intends to obtain approval for the use of level indicators are to submit an application (Specimen Form 7-4) filled in with necessary data and information to the Society (Head Office).

4.2.2 Applicant 1 Although, as a rule, the company submitting the application form of the preceding 4.2.1 are to be the manufacturers of the said devices, exceptions are made for those parties who are ultimately responsible for assuring the quality of the said devices. 2 Manufacturers of parts of the said devices may be considered as approval applicants in case approvals for the use of the parts are desired.

4.2.3 Documents Three copies each of the drawings and data in the following (1) through (9) are to be submitted together with the application form specified in 4.2.1. (1) Specifications of said devices (2) Construction drawings and summary of working principles of said devices (3) Approval test plan (including place and expected date of test) (4) Data on the summary of testing facilities of the same as above (5) Introduction of manufacturing plant (6) Information on the manufacturing and quality control standards of said devices (7) Manufacturing and delivery records of said devices (8) Technical information of the said devices (9) Other data deemed necessary by the Society

4.3 Preliminary Examinations

4.3.1 Approval of Test Plan The Society examines the approval test plan submitted under the requirements of 4.2.3(3), and where deemed appropriate, the plan is approved and returned to the applicant. In this case, when the Society examines the documents prescribed in 4.2.3, some part of the approval test items may be omitted.

4.3.2 Confirmation of Manufacturing and Quality Control Procedure On the basis of the data submitted in accordance with 4.2.3(4), (5), (6), (7) and (8), the Society may make


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investigation of the condition of manufacturing plant when deemed necessary.

4.4 Approval Test

4.4.1 Construction The construction of the level indicator is to satisfy the following requirements (1) through (6): (1) To be able to adequately withstand ship vibration, ship motions, trim and heel. (2) For devices which are used in tanks carrying flammable liquids, special consideration is to be given against

prevention of generation and charge of static electricity. (3) To be able to withstand the most severe pressure and temperature expected during working conditions and, for

parts in contact with the liquid, to have adequate compatibility between the device and the liquid considered. (4) The construction in addition of the above is also to be as follows:

(a) To be such that maintenance and inspection can be carried out easily and safely (b) To have appropriate devices installed to prevent metal fittings from coming loose.

(5) The adequate function to correct the specific gravity is to be equipped into a device as necessary. (6) For electrical parts of the level indicator which is installed within the dangerous zones as defined in Part N and

Part S of the Rules, to be of explosion protective construction as specified according to the requirements in each of the relevant parts.

4.4.2 Details of Test 1 The approval test is to include the following items (1) through (5) depending on application and type of level indicators. (1) In addition to conformity with the requirements in 4.4.1, confirmation of whether the tests specimen agrees with

the established specifications for completion, construction, dimensions and used parts. (2) Confirmation of whether the test specimen performs as specified where the configuration is in the regular

installed direction and in 22.5°inclined direction under the working condition given in the following: (a) Parts located out of the tank: normal temperature and maximum working pressure (b) Parts located inside the tank and on the tank walls: maximum and minimum working temperature (However,

where this temperature is within the range of 0 and 60, normal temperature may be used instead)and maximum working pressure

(3) For devices in which the liquid level is measured by use of floats and where the float is not fixed during navigation, confirmation of whether specified performance can be realized after a drop test in which the float is dropped from a height of 3 m onto a steel plate in 10 mm thickness. (However, where a damping device such as springs are provided at the top and bottom edge of the guide, tests may be carried out with such devices installed, although the tests are to be repeated at least ten times.)

(4) For devices in which the liquid level is measured by use of floats, confirmation of whether any damage occurs to the rubbing parts where the same equipped pipes and wires are set up horizontally and the float and guide are made to contact each other at the same places much as practicable. Then, for devices which the float is not fixed during navigation, rubbing tests which the float is slided 5,000 times between 5 m span are to be carried out.

(5) For the electrical parts of the said devices, the environmental tests are to be carried out with a satisfactory result. In application of these tests, the test items, the testing condition and method and the criteria are to be, in general, in accordance with the requirements specified in Chapter 1 of this Part. Where the environmental tests for the said devices are impracticable to comply with the testing condition and method and the criteria specified in Chapter 1 of this Part, they may be comply with an other recognized standard deemed appropriate by the Society.

2 Additional tests other than those of the preceding -1 may be requested, where deemed necessary by the Society.

4.4.3 Witness of Tests As a rule, the Society’s surveyor is to be present when carrying out the approval tests. However, attendance of the Society’s surveyor may not be necessary in case the said tests are carried out at the recognized official organization deemed appropriate by the Society.

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4.4.4 Test Records 1 After completion of the approval test, the manufacturer is to prepare a record of the approval test and is to submit three copies to the Society after getting verification by the surveyor of the Society. 2 Where the provision of 4.4.3 above applies, it is not necessary to verify by the Society’s surveyor for the test record by the recognized organization. 3 The record of the approval test of -1 above is to be appended with records relating to quality control implemented during the production of the test specimen.

4.5 Approval

4.5.1 Notice of Approval and Publicity 1 The Society, when satisfied upon examination of the submitted documents as required per 4.2 to 4.4 and the attending surveyor’s report, will approve the use of machinery equipment. In this case, the Society will issue a certificate of approval specifying the approval number, approval date, items of approval and approval conditions, put approval stamps on the documents as deemed necessary by the Society out of those submitted in accordance with 4.2.3 and 4.4.4, and return them back to the applicant. 2 The Society will make public the approval of per the level indicator.

4.5.2 Term of Validity The term of validity of the approval of level indicator is not to exceed four years from the date of approval.

4.5.3 Renewal of Approval 1 The manufacturer, who intends to have a continuation of the approval already expired or to make partial technical modifications of the level indicator, is to submit an application (see Form 7-5) in accordance with the requirements of 4.2 newly. In this case, the data required per 4.2.3 may be limited to the portion subjected to modification only. 2 Where approval is given for the partial modifications in the contents of approval, expiration date will not be renewed, in principle.

4.5.4 Revocation of Approval In case where either of the following (1) to (4) applies, the Society will revoke the approval for use of level indicators, and give notice to the manufacturer. (1) When renewal procedures were not undertaken without any special reason. (2) In association with the implementation or revision of international conventions, laws and regulations, the

machinery and equipment for which the approval was granted do not deserve the approval any longer. (3) When serious shortcomings are found in structure or quality of the level indicator already approved after being

installed in ships. (4) When an application for revocation is made by the manufacturer.


4.6.1 Tests and Inspection on the Individual Product Tests and inspection at the manufacturing plant of liquid level indicators which have been obtained the approval for use may be limited to those specified in the approved certificate mentioned in 4.5.1-1 notwithstanding the relevant requirement of the Rules and their Guidance

4.6.2 Marking Manufacturers are to mark the product before shipment for identification of approval equipment and, in addition, at least the following items are to be marked at the suitable place. (1) Name of manufacturer or equivalent, date of manufacture and serial number (2) Configuration number or symbol (3) Particulars or ratings


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Form 7-4

Part 7 Chapter 4

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Form 7-5


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Chapter 5 APPROVAL OF USE OF WATER LEVEL DETECTION AND ALARM SYSTEMS

5.1 General

5.1.1 Scope 1 The requirements in this chapter apply to tests and inspection for the approval of use in ships of water level detection and alarm systems installed in cargo holds, ballast tanks, cofferdams, etc., in accordance with the requirements in 13.8.5, Part D of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”), 2 The electrical devices used for water level detection and alarm systems are to be of those specified in accordance with the requirements in Chapter 5, Part 8 as appropriate.

5.1.2 Definition The water level detection and alarm system includes all parts of the system from the detector to the display.

5.2 Application

5.2.1 Application Form The company, who intends to obtain the approval of use of water level detection and alarm systems are to submit an application (Specimen Form 7-6) filled in with necessary data and information to the Society (Head Office).

5.2.2 Applicant 1 The company submitting the application form of the preceding 5.2.1 is to be a manufacturer of the said systems, except a party who is ultimately responsible for assuring the quality of the said devices. 2 Manufacturers of parts of the said systems may be allowed as an applicant for the approval of use regarding the parts.

5.2.3 Documents Three copies each of the drawings and data in the following (1) through (9) are to be submitted together with the application form specified in 5.2.1. (1) Specifications of the said systems including any limitation regarding the type of cargoes for the guarantee of

performance (2) Construction drawings and explanatory documents of the working principle of the said systems (3) Approval test plan (including place and expected date of test) (4) Explanatory documents of the testing facilities (5) Explanatory documents of the manufacturer (6) Explanatory documents on the manufacturing and quality control standards of the said systems (7) Manufacturing and delivery records of the said systems (8) Technical documents of the said devices including the manual specified in 13.8.5-4, Part D of the Rules (9) Other data deemed necessary by the Society

5.3 Preliminary Examinations

5.3.1 Approval of Test Plan The Society examines the approval test plan submitted under the requirements of 5.2.3(3), and where deemed appropriate, the plan is approved and returned to the applicant. When the Society examines the documents prescribed in 5.2.3 and considers appropriate, a part of the test items may be omitted.

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5.3.2 Confirmation of Manufacturing and Quality Control Procedure When deemed necessary, on the basis of the data submitted in accordance with 5.2.3(4), (5), (6), (7) and (8), the Society may request an on-site investigation of the manufacturer.

5.4 Approval Test

5.4.1 Construction and Function The construction and the function of the water level detection and alarm system is to satisfy the following requirements (1) through (5): (1) To be able to adequately withstand ship vibration, ship motions, trim and heel. (2) To be able to withstand the most severe pressure and temperature expected during working conditions and, for

parts in contact with the liquid, to have adequate compatibility between the device and the liquid considered. (3) The construction in addition to the above is to be as follows:

(a) maintenance and inspection can be carried out easily and safely. (b) appropriate means are provided to prevent metal fittings from coming loose.

(4) The construction and function specified in D13.8.5-3 of the Guidance for the Survey and Construction of Steel Ships (hereinafter, referred to as “the Guidance”) and the alarm function specified in 13.8.5-3, Part D of the Rules and D13.8.5-4 of the Guidance are to be provided.

(5) For the systems provided with override devices, the function specified in D13.8.5-5 of the Guidance is to be provided.

5.4.2 Details of Test 1 The approval test is to include the following items (1) through (5) depending on the application and the type of the water level detection and alarm system. (1) Confirmation whether the test specimen complies with the designated specifications for finishing, construction,

dimensions and parts or not, in addition to complying with the requirements in 5.4.1. (2) Pressure test of the test specimen for a period in accordance with the following (a) and (b). The test pressure is

to be a design pressure but not less than the pressure equivalent to seawater head of maximum depth of the space where the parts are fitted. (a) Parts fitted in ballast tank or cargo hold: 20 days (b) Parts fitted in adjacent spaces considered to be simultaneously flooded under damage stability calculations

of the spaces/tanks/cargo holds: 20 days (c) Parts fitted in spaces other than those specified in (a) or (b): 24 hours

(3) Confirmation whether the test specimen performs as specified or not, under the regular installed condition, inclining conditions of 22.5 degrees in transverse direction and 10 degrees in longitudinal direction at the following temperature: (a) Parts installed outside the cargo hold: normal temperature (b) Parts installed inside the cargo hold: maximum and minimum working temperature (Where this temperature

is expected within the range between 0 and 60, room temperature may be used) (4) For the systems installed in cargo holds, confirmation whether the test specimen detects seawater as specified or

not, by merging in a test mixture of fine materials of each intended cargoes in seawater (a solution of sodium chloride having a specific gravity of 1.025 g/cm3 may be accepted as an alternative to seawater) in accordance with the followings: (a) The concentration of fine materials in a test mixture is to be of minimum 50% by weight. In general, the

type of test mixture may be limited to the followings. The smallest and largest particle size together with the density of the dry mixture used in this test is to be ascertained and recorded in the test records and the manuals required by 13.8.5-4, Part D of the Rules. i) Minimum one type of fine mineral (dust of iron ore, coal, sand, etc. with particle size of, in general,

less than 0.1 mm) ii) Minimum one type of grain (barleycorn, wheat, corn, etc. with particle size of, in general, greater than

3 mm) (b) A sequence from immersion to detection is to be repeated minimum 10 times (a period of one sequence of


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the test is not to be less than 30 seconds as a standard) without cleaning any filtration arrangements. The pressure in the test mixture container is to be not more than 0.02 MPa at the sensor and any filter arrangement.

(c) When the test mixture is pumped into the test mixture container, the test mixture is to be kept in homogenized condition during the test and the effect of the pumping is not to affect the operation of the sensor and filter arrangements.

(5) For the electrical parts of the said systems, the environmental tests are to be carried out with a satisfactory result. In these tests, the test items, condition, method and criteria are to be, in general, in accordance with the requirements specified in Chapter 1 of this Part. Where it is impracticable to comply with the requirements specified in Chapter 1 of this Part, these tests may be in accordance with other recognized standards deemed appropriate by the Society.

2 Additional tests other than those in -1 may be requested, where deemed necessary by the Society.

5.4.3 Witness of Tests As a rule, the approval tests are to be carried out at the present of the Society’s surveyor. However, attendance of the Society’s surveyor may not be necessary in case the said tests are carried out at a recognized official organization deemed appropriate by the Society.

5.4.4 Test Records 1 After completion of the approval test, the manufacturer is to prepare a record of the approval test and is to submit three copies to the Society after verification by the attending surveyor. 2 Where the provision of 5.4.3 above applies, the verification by the surveyor is not required for the test record prepared by the recognized organization. 3 The records relating to quality control implemented during the production of the test specimen are to be attached to the record of the approval test in -1 above.

5.5 Approval

5.5.1 Notice of Approval and Publicity 1 The Society, when satisfied upon examination of the submitted documents as required per 5.2 to 5.4 and the attending surveyor’s report, will approve the use of the water level detection and alarm system. In this case, the Society will issue a certificate of approval specifying the approval number, approval date, items of approval and approval conditions, and put approval stamps on the documents as deemed necessary by the Society out of those submitted in accordance with 5.2.3 and 5.4.4, and return them back to the applicant. 2 The Society will make public the approval of the water level detection and alarm system.

5.5.2 Term of Validity The term of validity of the approval is not to exceed five years from the date of approval.

5.5.3 Renewal of Approval 1 The manufacturer, who intends to have a continuation of the approval to be expired or to make partial technical modifications of the system, is to submit an application (see Form 7-7) in accordance with the requirements of 5.2 newly. In this case, the data required per 5.2.3 may be limited to the portion subjected to modification only. 2 Where approval is given for the partial modifications in the contents of approval, expiration date will not be renewed, in principle.

5.5.4 Revocation of Approval In case where either of the following (1) to (4) applies, the Society will revoke the approval of use of the water level detection and alarm system, and give a notice to the manufacturer. (1) When renewal procedures were not undertaken without any special reason. (2) In association with the implementation or revision of international conventions, laws and regulations, the system

for which the approval was granted do not deserve the approval any longer. (3) When serious shortcomings are found in structure or quality of the water level detection and alarm system

already approved after being installed in ships.

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(4) When an application for revocation is made by the manufacturer.


5.6.1 Tests and Inspection on the Individual Product Tests and inspection at the manufacturer of the water level detection and alarm systems which has been obtained the approval of use may be limited to those specified in the approved certificate mentioned in 5.5.1-1 notwithstanding the relevant requirement of the Rules and their Guidance

5.6.2 Marking Manufacturers are to mark the product before shipment for identification of approval equipment and, in addition, at least the following items are to be marked at the suitable place. (1) Name of manufacturer or equivalent, date of manufacture and serial number (2) Configuration number or symbol (3) Particulars or ratings


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Form 7-6

Part 7 Chapter 5

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Form 7-7


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Chapter 6 APPROVAL OF USE OF CRANKCASE OIL MIST DETECTION ARRANGEMENTS

6.1 General

6.1.1 Scope The requirements in this Chapter apply to testing and inspection for use of crankcase oil mist detection

arrangements in accordance with the requirements of 2.4.5 Part D of the Rules for the Survey and Construction of Steel Ships.

6.2 Application

6.2.1 Application Form The manufacturer, who intends to obtain the approval of use, is to submit an application (Specimen Form 7-8)

filled in with necessary data and information to the Society (Head office).

6.2.2 Documents The documents listed (1) through (10) below, each in triplicate, are to be submitted together with the application

form specified in 6.2.1. (1) Specifications (2) Construction drawings and summary of working principles (3) Description of oil mist detection/monitoring equipment and system including alarms (4) Schematic layout of oil mist detection arrangements showing location of detectors/sensors and piping

arrangements and dimensions (5) Maintenance and test manual which is to include the following information:

(a) Intended use of equipment and its operation (b) Functionality tests (c) Maintenance routines and spare parts recommendations (d) Limit setting and instructions for safe limit levels (e) Where necessary, details of configurations in which the equipment is and is not to be used

(6) Approval test plan (the place of test and scheduled date of test are to be entered) (7) Data on the summary of test facilities (8) Information on the manufacturing and quality control standards (9) Records of manufacture and delivery (10) Others which are considered necessary by the Society

6.3 Approval Tests

6.3.1 General 1 The oil mist detection arrangements are to be tested in accordance with 6.3.2 and 6.3.3. 2 Test specimens are to be selected from the manufacturer's usual production line. 3 Test facilities are to comply with the followings: (1) The test facilities are to have the full range of facilities for carrying tests required by this chapter and be

approved by the society. (2) The test facilities that verify that the equipment ascertains the levels of oil mist concentration are to be equipped

so that they can control, measure and record oil mist concentration levels in terms of mg/l to an accuracy of ±10%.

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6.3.2 Environmental Test Environmental tests specified in (1) and (2) below are to be carried out with a satisfactory result. The test condition

and method and the criteria are to be in accordance with the requirements specified in 1.3.1 of this part. (1) For alarm/monitoring panel:

(a) Electrical power supply failure test (b) Electrical power supply fluctuation test (c) Dry heat test (d) Damp heat test (e) Vibration test (f) Insulation resistance test (g) High voltage test (h) Inclination test (to be applied to equipment with moving parts) (i) Electrostatic discharge immunity test (to be applied to electronic devices) (j) Radiated radio frequency immunity test (to be applied to electronic devices) (k) Conducted low frequency immunity test (to be applied to electronic devices) (l) Conducted high frequency immunity test (to be applied to electronic devices) (m) Burst/Fast transient immunity test (to be applied to electronic devices) (n) Surge immunity test (to be applied to electronic devices) (o) Radiated emission test (to be applied to electronic devices that emit the electromagnetic wave) (p) Conducted emission test (to be applied to electronic devices that emit the electromagnetic wave)

(2) For the detectors: (a) Electrical power supply failure test (b) Electrical power supply fluctuation test (c) Dry heat test (d) Damp heat test (e) Vibration test (f) Insulation resistance test (g) High voltage test (h) Inclination test (to be applied to equipment with moving parts)

6.3.3 Functional Test 1 Two sets of detectors/monitors requiring approval are to be subjected to the following tests. One set is to be tested in the clean condition and the other in a condition that represents the maximum degree of lens obscuration that is stated as being acceptable by the manufacturer. They are to be tested in the orientation in which they intended to be installed on an engine or gear case. An oil mist concentration to be used for testing is to be an accuracy of ±10%. (1) The concentration of oil mist in the test vessel is to be measured in the top and bottom of the vessel and is not to

differ by more than 10%. (2) It is to be verified that the oil mist detection arrangements are capable of detecting oil mist in air concentrations

of between 0 and 10% of the lower explosive limit (LEL) or more than 2 times of alarm set point. (3) The operation of the alarm indicators for oil mist concentration in air is to be verified and is to provide an alarm

at a maximum setting not more than 5% of the LEL (corresponding to approximately 2.5 mg/l). Where alarm set points can be altered, the means of adjustment and indication are to be verified against the equipment manufacturer's instructions.

(4) Where oil mist is drawn into a detector/monitor via piping arrangements, the time delay between the sample leaving the crankcase and operation of the alarm is to be determined for the longest and shortest lengths of pipes recommended by the manufacturer. The pipe arrangements are to be in accordance with the manufacturer's instructions.

2 The oil mist concentrations are to be ascertained by the gravimetric deterministic method or equivalent. The gravimetric deterministic method is a laboratory process where the difference in weight of milipore (pore size: typically 0.8 µm) filter is ascertained from weighing the filter before and after drawing 1 m3 of oil mist through the filter. The filters are to be weighed to a precision of 0.1 mg and the volume of the oil mist sampled to 10 ml. The results of a gravimetric analysis are considered invalid and are to be rejected in case of the following situations.


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(1) In case where the resultant calibration curve has an increasing gradient with respect to the oil mist detection/monitoring reading. (This situation occurs when insufficient time has been allowed for the oil mist to become homogeneous.)

(2) In case where single results of a gravimetric analysis are more than 10% below the calibration curve. (This situation occurs when the integrity of the filter unit has been compromised and not all of the oil is collected on the filter paper.)

3 The details of detection/monitoring devices to be tested are to be recorded. This is to include manufacturer, type designation, oil mist concentration assessment capability and alarm settings. 4 After completing the tests, the detection/monitoring devices are to be examined and the condition of all components ascertained and documented. Photographic records of the monitoring devices condition are to be taken and included in the report.

6.3.4 Witness of Tests For cases where test samples are identified or where the approval test is carried out, they are, in principle, at the

presence of the Society's surveyor.

6.3.5 Test Records The manufacturer is to prepare records of the approval test including the following information and documents

after completion of the test, to obtain verification by the Society's attending surveyor and to submit them, in triplicate, to the Society. (1) Test specification (2) Details of devices tested (3) Results of tests in 6.3.2 and 6.3.3 above

6.4 Approval

6.4.1 Notification of Approval The Society, when satisfied upon examination of the submitted documents as required per 6.2 and 6.3 and the

attending surveyor's report, will issue a certificate of approval specifying the approval number, approval date, items of approval and approval conditions, put approval stamps on the documents as deemed necessary by the Society out of those submitted in accordance with 6.2.2 and 6.3.5, and return them back to the applicant.


6.4.3 Revocation of Approval In case where either of the following (1) through (4) applies, the Society will revoke the type approval of

machinery and equipment, and give notice to the manufacturer. (1) In association with the implementation or revision of international conventions, laws, and regulations, the




6.5.1 Tests and Inspection on the Individual Product Test and inspection at the manufacturer and on board of the oil mist detection arrangements which has been

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obtained the approval of use may be limited to those specified in the approved certificate mentioned in 6.4.1 notwithstanding the relevant requirement of the Rules and their Guidance.

Form 7-8

APPLICATION FOR APPROVAL OF USE OF CRANKCASE OIL MIST DETECTION ARRANGEMENTS

( Initial, Renewal, Modification)

To: Machinery Department, NIPPON KAIJI KYOKAI 4-7, Kioi-cho, Chiyoda-ku, Tokyo 102-8567, JAPAN Ref. No.: Date:

Name of Applicant:

Address:

Phone No./Fax. No.:

Name of the Person in Charge: We hereby apply for type approval of the following arrangement in accordance with the requirements of Chapter 6, Part 7 of the Guidance for the Approval of Materials and Equipment for Marine Use of Nippon Kaiji Kyokai.

Names/Types of arrangement

Type approval Nos. If Available

Particulars

Names of Manufacturer and Production Site

Address of Manufacturer

Drawings

Drawings and Documents Attached Documents

Date of Tests/Inspections and Places

Notes: 1. Use additional sheets if necessary. 2. Tick off where appropriate


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Part 8 TYPE TESTS OF ELECTRICAL EQUIPMENT AND CABLES

Chapter 1 GENERAL

1.1 General

1.1.1 Scope The requirements in this part apply to tests and inspection for the type test of electrical equipment and cables specified in 1.1.3 in accordance with the requirements of 1.2.1-4, Part H of the Rules for the Survey and Construction of Steel Ships (hereinafter referred to as “the Rules”).

1.1.2 Definitions The type tested products are those certified that they have passed through the type tests specified in Chapter 2 to 6.

1.1.3 Articles Electrical equipment cables subject to the type test are to bo as follows. (1) Fuses

Catridge type fuses (renewable and non-renewable) and plug type fuses used for the protection of the electric circuits of 500 V a.c. or below in frequency of 50 Hz or 60 Hz or 250 V d.c. or below.

(2) Circuit breakers Low-voltage breakers, air circuit breakers and molded case circuit breakers (including molded case circuit breakers with fuses and molded case circuit breakers used for the protection of induction motors simultaneously. Hereinafter, these are referred to as “molded case circuit breakers” unless otherwise specified.), used for protection of the electric circuits of 500 V a.c. or below (rated operational voltage) of 50 Hz or 60 Hz in frequency or 500 V d.c. or below.

(3) Electromagnetic contactors Electromagnetic contactors used for motors and other loads connected to the electric circuits of 500 V a.c. or below (rated operational voltage) of 50 Hz or 60 Hz in frequency or 500 V d.c. or below.

(4) Explosion protected electrical equipment Electrical equipment of the flameproof type, intinsically safe type, increased safety type and pressurized protected type (limited to sealed type) used in the spaces on board flammable or explosive gas or vapour (hereinafter referred to as explosive gas) exists or may exist in the atmosphere.

(5) Cables (a) Cables used power circuits, lighting circuits, supply and distribution circuits of interior-communication,

control circuits, etc. (b) Flexible cords used for power supply and distribution circuits. (c) 150 V multicore PVC insulated cables for electronic equipment.


The application procedures are to be as follows: (1) The manufacturer who intends to obtain the type tests by the Society is to submit an application (see Form 8-1)

stating names, types, ratings, specifications, service applications, applicable standards, etc. of the products concerned together with three copies each of drawings and documents necessary for examinations and three copies of test plans. In case where items of the type tests are intended to be partially of fully omitted appropriate certificate or technical records concerned are to be submitted to the Society as well. In addition, the application is, in principle, to be prepared for each type.

(2) As for explosion protected electrical equipment, drawings and documents required to be submitted are as

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follows. Items (d), (e) and (f) are, however, required for intrinsically safe type electrical equipment only. (a) Drawings of detailed sectional assembly and arrangement of components (b) List of electrical parts and materials (c) Functional descriptions of explosion-protected constructions (d) Electric circuit diagrams (e) Sectional assembly drawings of transformers with earthed screens and component parts (relays,

photo-couplers, etc.) used for maintenance of intrinsic safety (f) Construction drawings and circuit diagrams of safety barriers.

1.3 Type Tests

1.3.1 Test Place Tests are, in principle, to be carried out at the manufacture’s works in the presence of the Society’s surveyor.

1.3.2 Type Tests Detailed requirements of type tests are to be in accordance with Chapters 2 to 6 according to the types of equipment. In case where the Society deems necessary, however, additional tests may be requested.

1.4 Certificate

1.4.1 Submission of Test Records The manufacturer (applicant) is to submit three copies each of the test records to the Society (Branch Office) immediately after completion of tests.

1.4.2 Issuance of Certificate The Society issues certificates for the type tested products, where the results of the type tests are deemed satisfactory. In this case, one copy of the test records submitted in accordance with 1.4.1 is returned to the applicant (through the related local office) after putting the Society’s stamp.

1.4.3 Term of Validity The term of validity is four full years from the date of passing the type tests.

1.4.4 Renewal of Validity 1 Where the validity of the certificate is intended to be renewed, the manufacturer is to undergo the periodical investigation (see 1.5) after submitting an application (see Form 8-1) to the Society (Branch Office). 2 Where the periodical investigation is postponed due to unavoidable reasons, the manufacturer is to take the steps required by the Society. 3 Where the periodical investigation has been passed, the Society will re-issue the new certificate, the term of validity of which is four years from the date of passing the periodical investigation. 4 When the validity of the certificate is not intended to be renewed, the manufacturer is to notify the Society (Branch Office) in writing and immediately return the certificates of the products concerned.

1.5 Periodical Investigation

1.5.1 Place of Investigation The periodical investigation is, in principle, to be carried out at the manufacturer’s works in the presence of the Society’s surveyor.

1.5.2 Tests Test items and the number of test samples for the periodical investigation are to be in accordance with the requirements specified in 1.3. The following test items, however, may be omitted. (1) Breaking capacity test of fuses (2) Short-time withstand current test, short-circuit test, overload test, endurance test and coordination test of circuit

breakers


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(3) Number of operating cycles test and life test of electromagnetic contactors (4) Explosion-withstand test and flame-propagation test of flameproof type electrical equipment (5) Spark ignition test of intrinsically safe type electrical equipment

1.6 Change of Materials and Constructions, etc.

1.6.1 Application for Change Where the particulars, materials of essential parts, construction, dimensions, etc. of the type tested products are intended to change, the manufacturer is to submit an application for the change (see Form 8-1) and three copies each of explanatory notes of the change (writing in contrasted form of new and old ones as far as possible) and necessary drawings to the Society. Verification tests may be carried out where deemed necessary in connection with the changes.

1.7 Verification Test

1.7.1 Execution of Test 1 In case of applying to any of the followings, the verification tests are to be carried out. The tests are, in principle, to be carried out at the manufacturer’s works. (1) Where tests are carried out in accordance with 1.6.1. (2) Where doubts occur in the construction, performance, etc. of the type tested products. (3) Where deemed necessary by the Society. 2 Items of the tests are to be defined at each case in accordance with the purpose.

1.7.2 Submission of Certificate and Test Record The manufacturer is to submit the existing certificates and three copies each of the test records to the Society (Branch Office) immediately after completion of the verification test.

1.7.3 Renewal of Certificate Where verification test records are considered appropriate the Society will issue the new certificates.

1.8 Revocation of Certificate

1.8.1 Notice of Revocation Where the results of the periodical investigation or verification tests are found unsatisfactory or where the application for the periodical investigation is not made, the Society will notify the manufacturer of the revocation of the approval through the Branch Office.

1.8.2 Return of Certificate The manufacturer who received the revocation specified in 1.8.1 is to immediately return the certificates concerned to the Society.

1.9 Treatment of Product after Success in Type Test

1.9.1 Tests and Inspection of Individual Product 1 The manufacturer is to file the test records of the necessary delivery tests for the type tested products. 2 The test records are to be immediately presented where requested by the Society’s surveyor.

1.10 Markings

1.10.1 Markings The marking of the type tested products are to be in accordance with the Rules and Application Standard (including the manufacturer’s name or equivalent, type No. or code, manufacturing No., year, main particulars and ratings) and in addition, the manufacturer is to mark appropriately to indicate the type tested product.

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Form 8-1

Note :

1. In case of shortage of space, fill out in a separate sheet(s). 2. Check the item concerned. Take off unnecessary characters with lines.


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Chapter 2 FUSES

2.1 General

2.1.1 Scope 1 The requirements in this chapter apply to the type tests of fuses in accordance with the requirements in Chapter 1. 2 For items especially provided in this chapter, the requirements in this chapter are applied in lieu of the requirements in Chapter 1.

2.2 Type Tests

2.2.1 Type Tests Detailed requirements of the type test are to be in accordance with IEC 60269 (Low-voltage fuses) or a standard which is deemed appropriate by the Society, amended when necessary for ambient temperature.

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Chapter 3 CIRCUIT-BREAKERS

3.1 General

3.1.1 Scope 1 The requirements in this chapter apply to the type tests of circuit-breakers in accodance with the requirements in Chapter 1. 2 For items especially provided in this chapter, the requirements in this chapter apply in lieu of the requirements in Chapter 1.

3.2 Type Tests

3.2.1 Type Tests Detailed requirements of the type test are to be in accordance with IEC 60947-1 (Low-voltage switchgear and controlgear - Part 1: General) and 60947-2 (Low-voltage switchgear and controlgear - Part 2: Circuit-breakers), 60157-1 (Low-voltage switchgear and controlgear - Part 1: Circuit-Breakers) or a standard which is deemed appropriate by the Society, amended when necessary for ambient temperature.


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Chapter 4 ELECTROMAGNETIC CONTACTORS

4.1 General

4.1.1 Scope 1 The requirements in this chapter apply to the type tests of electromagnetic contactors in accordance with the requirements in Chapter 1. 2 For items specially provided in this chapter the requirements in this chapter apply in lieu of the requirements in Chapter 1.

4.2 Type Tests

4.2.1 Type Tests Detailed requirements of the type test are to be in accordance with IEC 60947-1 (Low-voltage switchgear and controlgear - Part 1: General) and 60947-4 (Low-voltage switchgear and controlgear - Part 4: Contactors and motor starters), 60158-1 (Low-voltage controlgear - Part 1: Contactors) or a standard which is deemed appropriate by the Society, amended when necessary for ambient temperature.

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Chapter 5 EXPLOSION-PROTECTED ELECTRICAL EQUIPMENT

5.1 General

5.1.1 Scope 1 The requirements in this chapter apply to the type tests of explosion-protected electrical equipment in accordance with the requirements in Chapter 1. 2 For items specially provided in this chapter, the requirements in this chapter apply in lieu of the requirements in Chapter 1.

5.2 Type Tests

5.2.1 Type Tests Detailed requirements of the type test are to be in accordance with IEC 60079 (Electrical apparatus for explosive atmospheres) or a standard which is deemed appropriate by the Society, amended when necessary for ambient temperature.


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Chapter 6 CABLES

6.1 General

6.1.1 Scope 1 The requirements in this chapter apply to the type tests of cables in accordance with the requirements in Chapter 1. 2 For items specially provided in this chapter, the requirements in this chapter apply in lieu of the requirements in Chapter 1.

6.2 Type Tests

6.2.1 Type Tests Detailed requirements of the type test are to be in accordance with IEC 60092 (Electrical installations in ships) or a standard which is deemed appropriate by the Society, amended when necessary for ambient temperature.

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Annex 1 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL AND PRODUCTION TESTS OF LIFEBOATS

Chapter 1 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL OF LIFEBOATS

1.1 Material Test

1.1.1 Material Test for Boat Hulls and Rigid Covers The materials of boat hulls and rigid covers made of materials other than metals are to be subjected to the following tests : (1) Fire-redundancy Test :

[6.2.1] (Paragraph on IMO Resolution A.689(17) for Reference) [Reg. 41-1.3] (Regulation and paragraph on Chapter III of SOLAS Convention for reference) (a) The test is to be carried out in accordance with 5.24 “Fire Retarding Characteristics A Method” of JIS K

6911 “Testing Methods for Thermosetting Plastics”. The burning time and burning distance, measured after the test, are to be less than 180 seconds and not more than 25 mm respectively;

(b) Where there are any difficulties in conducting the test in accordance with (a) above, an equivalent test procedure may be acceptable.

(2) Material Test for FRP Where the material is FRP, tests are to be carried out in respect of the following and it is to be ascertained that they conform to the design standards of the manufacturer : (a) Glass contents; (b) Tensile Strength; (c) Bending strength; (d) Barcol hardness.

1.1.2 Material Test for Buoyant Materials [6.2.2～6.2.7] [Reg. 41-4] The dimensions of a test specimen are to be 300 mm×300 mm×150 mm. (1) Test for Stability under Temperature Cycling (Six specimens) [2.7.1～2.7.4]

The dimensions of test specimens are to be measured at the beginning and end of the tests. (a) Specimens are to be alternately subjected for 8 hours to surrounding temperatures of -30 and +65 and

subjected for ten cycles. These alternating cycles need not follow immediately after each other and the following procedure, i) and ii), repeated for ten cycles, is acceptable : i) First Day

The specimens are to be exposed for 8 hours to the surrounding temperature of +65. They are then to be removed from the warm chamber, and are to be left exposed under ordinary room conditions until the next day;

ii) Second Day The specimens subjected to the tests referred to in i) above are to be exposed for 8 hours to the surrounding temperature of -30. They are then to be removed from the cold chamber, and are to be left exposed under ordinary room conditions until the next day. As a result of the tests, the specimens are to show no sign of external change of structure or of mechanical qualities.

(b) Two of the specimens subjected to the tests referred to in (a) are to be cut open and are to show no sign of internal change of structure.

2 Test for Water Absorption [2.7.5～2.7.8] (1) The test specimens are to be the following six :


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(a) two specimens as supplied; (b) two specimens which have been subjected to the temperature cycling as prescribed in 1.1.2-1; and (c) two specimens which have been subjected to the temperature cycling as prescribed in 1.1.2-1 followed by

the immersion for a period of 24 hours under a 100 mm head of high octane petroleum spirit at normal room temperature.

(2) The dimensions of the test specimens are to be measured at the beginning and end of these tests. (3) The specimens are to be immersed for a period of seven days under a 1.25 m head of fresh water. (4) The mass (in kilograms) which each specimen could support out of the water after 1 and 7 days immersion is to

be measured. (5) As a result of the tests, the reduction ratio of buoyancy of the 7 days immersion specimen to the 1 day

immersion specimen is not to exceed 5%. The specimens are to show no sign of damage such as shrinking, cracking, swelling or changes of mechanical qualities.

3 Oil resistance Test [6.2.3, 6.2.4, 6.2.6, 6.2.7] Two specimens of the material are each to be immersed in each of the following for a period of 14 days under a

100 mm head. These tests are to be carried out at normal room temperature (approximately 18). The dimensions of the specimens are to be measured at the beginning and end of these tests : (1) crude oil; (2) fuel oil; (3) diesel oil; (4) high octane petroleum spirit; and (5) kerosene.

The mass (in kilograms) which each specimen could support out of the water after 14 days immersion is to be measured. The reduction ratio of buoyancy after 14 days immersion is not to exceed 5%, and the specimens are to show no sign of damage such as shrinking, cracking, swelling, dissolution or change of mechanical qualities.

1.2 Strength and Performance Tests

1.2.1 General [6.1] 1 The mass of an average person as used herein is to be taken to be 75 kg. 2 When weights are placed to represent the persons in the lifeboat, the centre of gravity of the weight in each seat is to be placed 300 mm above the seatpan along the seat back.

1.2.2 Launch Test [6.3] It is to be demonstrated that the fully equipped lifeboat, loaded with a properly distributed mass equal to the mass of the number of persons for which it is to be approved, can be launched from a ship proceeding ahead at a speed of not less than 5 knots in calm water and on an even keel. There is to be no damage to the lifeboat or its equipment as a result of this test.

1.2.3 Lifeboat Overload Test [6.4] 1 Davit-launched Lifeboats [6.4.1～6.4.6] (1)

(a) The unloaded lifeboat is to be placed on blocks or suspended from the lifting hooks. The measurements required in (d) are then to be made. Where the unloaded lifeboat is placed on blocks, the position of the blocks is to correspond to the position of the lifting hooks.

(b) The lifeboat is to then be loaded with properly distributed weights to represent the fully equipped lifeboat loaded with the full complement of persons for which it is to be approved. The measurements required in (d) are again to be made.

(c) Additional weights are then to be added so that the suspended load is 25%, 50%, 75% and 100% greater than the weight of the fully equipped and loaded lifeboat. In the case of metal lifeboats, the testing is to stop at 25% overload. The weights for the various overload conditions are to be distributed in proportion to the loading of the lifeboat in its service condition, but the weights used to represent the persons need not be placed 300 mm above the seatpan. Testing by filling the lifeboat with water are not to be accepted as this method of loading does not give the proper distribution of weight. Machinery may be removed in order to

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avoid damage to it, in which case weights are to be added to the lifeboats to compensate for the removal of such machinery. At each incremental overload, the measurements required in (d) are to be made.

(d) The following are to be measured and recorded at each condition of load specified in (a) through (c) : i) deflection of keel amidships; ii) change in length as measured between the top of stem and stern posts; iii) change in breadth over the gunwale at the quarter length forward, amidships and the quarter length aft;

and iv) change in depth measured from gunwale to keel.

(e) The keel deflection and change in breadth in (1)(d)i) and (1)(d)iii) are not to exceed 1/400 of the lifeboat’s length when the lifeboat is subjected to 25% overload; the results at 100% overload, if required by (1)(c), are to be approximately in proportion to those obtained at 25% overload.

(f) The weights are then to be removed and the dimensions of the lifeboat checked. The residual deflection is not to exceed 1/1000 of the lifeboat’s length. Any permanent deflection as a result of these tests is to be recorded. If the lifeboat is made of GRP, such measurement is to be taken after a lapse of time sufficient to permit the GRP to recover its original form (approximately 18 hours).

2 Free-fall Lifeboats [6.4.7～6.4.9] (1) It is to be demonstrated that the lifeboat has sufficient strength to withstand the forces acting upon it when

loaded with a distributed mass equal to the mass of the number of persons for which it is to be approved and its equipment when free-fall launched from a height of 1.3 times the height for which it is to be approved. If the lifeboat is normally ramp-launched, and a ramp is not available, this test may be conducted by dropping the lifeboat vertically with the keel at the same angle that normally occurs during water entry.

(2) After this test the lifeboat is to be unloaded, cleaned and carefully examined to detect the position and extent of damage that may have occurred as a result of this test. An operational test is then to be conducted in accordance with 1.2.10-1. After this test the lifeboat is again to be unloaded, cleaned, and inspected for possible damage.

(3) This test is to be considered successful if the operational test is satisfactory and there is no significant damage to it.

1.2.4 Davit-launched Lifeboat Impact and Drop Test [6.5.1, 6.5.2] 1 Impact Test (1) The fully equipped lifeboat, including its engine, is to be loaded with weights equal to the mass of the number of

persons for which the lifeboat is to be approved. The weights are to be distributed to represent the normal loading in the lifeboat. Skates or fenders, if required, are to be in position. The lifeboat, in a free hanging position, is to be pulled laterally to a position so that when released it will strike a fixed rigid vertical surface at a velocity of 3.5 m/s. It is then to be released to impact against the rigid vertical surface.

(2) In the case of self-righting partially enclosed and totally enclosed lifeboats, the acceleration forces are to be measured and evaluated in accordance with 1.2.18 at different positions within the prototype lifeboat to determine the most severe occupant exposure to acceleration considering the effects of fenders, lifeboat elasticity, and seating arrangement.

2 Drop Test [6.5.3, 6.5.4] (1) The fully equipped lifeboat, with its engine, is to be loaded with weights equal to the mass of the maximum

number of persons for which the lifeboat is to be approved. The weights are to be distributed to represent the normal loading condition but need not be placed 300 mm above the seatpan. The lifeboat is then to be suspended above the water so that the distance from the lowest point of the lifeboat to the water is 3 m. The lifeboat is then to be released so that it falls freely into the water.

(2) The drop test is to be conducted with the lifeboat that was used in the impact test. 3 Operational Test After Impact and Drop Tests [6.5.5]

After the impact and drop tests, the lifeboat is to be unloaded, cleaned and carefully examined to detect the position and extent of damage that may have occurred as a result of the tests. An operational test is then to be conducted in accordance with 1.2.10-1. 4 Acceptability Criteria for Impact and Drop Tests [6.5.6, 6.5.7] (1) After the tests required in 1.2.4-1 to 1.2.4-3, the lifeboat is to be unloaded, cleaned, and inspected for possible

damage.


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(2) The impact and drop tests are to be considered successful if : (a) no damage has been sustained that would affect the lifeboat’s efficient functioning; (b) the damage caused by the impact and drop tests has not increased significantly as a result of the test

specified in 1.2.4-3; (c) machinery and other equipment has operated to full satisfaction; (d) no significant ingress of seawater has occurred; and (e) accelerations measured during the impact and subsequent rebound, if required during the impact test, are in

compliance with the criteria of either 1.2.18-3(1) to 1.2.18-3(4) or 1.2.18-4(1) to 1.2.18-4(5) when using the emergency limits specified in Table 2 or Table 3, respectively.

1.2.5 Free-fall Lifeboat Free-fall Test [6.6] 1 Free-fall Tests [6.6.1～6.6.3] (1) A lifeboat designed for free-fall launching is to be subjected to test launches conducted from the height for

which the lifeboat is to be approved taking into account conditions of unfavourable list (10°) and trim (20°), unfavourable locations of the centre of gravity, and extreme conditions of load.

(2) During the free-fall launches, acceleration forces are to be measured and the data evaluated in accordance with 1.2.18 at different locations in the lifeboat to determine the worst occupant exposure to acceleration taking into consideration the seating arrangement.

(3) The tests may be conducted with correctly scaled models that are at least 1 m in length. As a minimum, the dimensions and mass of the lifeboat, the location of its centre of gravity, and its second moment of mass, is to be scaled in a reasonable manner. Depending on the construction and behaviour of the free-fall lifeboat, other parameters may also have to be reasonably scaled to effect correct behaviour of the model. If models are used, sufficient full-scale tests are to be conducted to verify the accuracy of the model measurements. As a minimum, the following full-scale tests are to be conducted with the ship on an even keel using the same type of launching arrangement as the production lifeboat and from the height for which the lifeboat is to be approved : (a) lifeboat fully loaded; (b) lifeboat loaded with its required equipment and minimum launching crew only; (c) lifeboat loaded with its required equipment and one half of the full complement of persons distributed in

the forward half of the seating positions of the lifeboat; and (d) lifeboat loaded with its required equipment and one half of the full complement of persons seated in the

after half of the seating positions of the lifeboat. 2 Acceptability Criteria for Free-fall Tests [6.6.4] (1) The free-fall tests required in 1.2.5-1 are to be considered acceptable if :

(a) the acceleration forces are in compliance with the “Training” condition specified in Table 2 and Table 3 of 1.2.18 during the launch, free-fall, and subsequent water entry for those tests with the ship on even keel;

(b) the acceleration forces are in compliance with the “Emergency” condition specified in Table 2 and Table 3 of 1.2.18 during the launch, free-fall, and subsequent water entry for those tests with the ship under unfavourable conditions of list and trim;

(c) the lifeboat makes positive headway immediately after water entry.

1.2.6 Lifeboat Seating Strength Test [6.7] 1 Davit-launched Lifeboats [6.7.1]

The seating is to be loaded with a mass of 100 kg in each position allocated for a person to sit in the lifeboat. The seating is to be able to support this loading without any permanent deformation or damage. 2 Free-fall Lifeboats [6.7.2]

The seats experiencing the highest acceleration forces, and those seats which are supported in a manner different from the other seats in the lifeboat, are to be loaded with a mass of 100 kg. The load is to be arranged in the seat so that both the seatback and the seatpan are affected. The seating is to be able to support this load during a free-fall launch from a height of 1.3 times the approved height, without any permanent deformation or damage. This test may be conducted as part of the test in 1.2.3-2(1) to 1.2.3-2(3).

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1.2.7 Lifeboat Seating Space Test [6.8] 1 Boarding and Seating Test [6.8.1]

The lifeboat is to be fitted with its engine and its equipment. The number of persons for which the lifeboat is to be approved having an average mass of 75 kg and wearing a lifejacket and any other essential equipment is to be able to board the lifeboat and be properly seated within a period of 3 min in the case of a lifeboat intended for a cargo ship and as rapidly as possible in the case of a lifeboat intended for a passenger ship. The lifeboat is then to be manoeuvred and all equipment on board tested by an individual to demonstrate that the equipment can be operated without difficulty and without interference with the occupants. 2 Non-skid Finish Inspection [6.8.2]

The surfaces on which persons might walk are to be visually examined to determine that they have a non-skid finish.

1.2.8 Lifeboat Freeboard and Stability Tests [6.9] 1 Flooded Stability Test [6.9.1～6.9.3] (1)

(a) The lifeboat is to be loaded with its equipment. If provision lockers, water tanks and fuel tanks cannot be removed, they are to be flooded or filled to the final waterline resulting from the test in -2. Lifeboats fitted with watertight stowage compartments to accommodate individual drinking water containers are to have these containers abroad and placed in the stowage compartments which are to be sealed watertight during the flooding tests. Ballast of equivalent weight and density is to be substituted for the engine and any other installed equipment that can be damaged by water.

(b) Weights representing persons who would be in the water when the lifeboat is flooded may be omitted. Weights representing persons who would not be in the water when the lifeboat is flooded are to be placed in the normal seating positions of such persons.

(2) When loaded as specified in (1)(a) and (1)(b), the lifeboat is to have positive stability when filled with water to represent flooding which would occur when the lifeboat is holed in any one location below the waterline assuming no loss of buoyancy material and no other damage. Several tests may have to be conducted if holes in different areas would create different flooding conditions.

(3) The flooded stability may be substituted by calculations instead of the above test where circumstances does not permit the test.

2 Freeboard Test [6.9.4, 6.9.5] (1) The lifeboat with its engine is to be loaded with a mass equal to that of all the equipment. One half of the

number of persons for which the lifeboat is to be approved is to be seated in a proper seating position on one side of the centreline. The freeboard is then to be measured on the low side.

(2) This test is to be considered successful if the measured freeboard on the low side is not less than 1.5% of the lifeboat’s length or 100 mm, whichever is greater.

1.2.9 Release Mechanism Test [6.10] 1 Davit-launched Lifeboats [6.10.1～6.10.2] (1) The lifeboat with its engine fitted is to be suspended from the release mechanism just clear of the ground or the

water. The lifeboat is to be loaded so that the total mass equals 1.1 times the mass of the lifeboat, all its equipment and the number of persons for which the lifeboat is to be approved. The lifeboat is to be released simultaneously from each fall to which it is connected without binding or damage to any part of the lifeboat or the release mechanism.

(2) It is to be confirmed that the lifeboat will simultaneously release from each fall to which it is connected when fully waterborne in the fully loaded condition without a mass of the number of persons for which the lifeboat is to be approved, and in a 10% overload condition.

(3) The release mechanism is to be mounted on a tensile strength testing device. The load is to be increased to at least six times the safe working load of the release mechanism without failure of the release mechanism. The safe working load of the release mechanism is a load exerted to the release mechanism when it is assumed that a mass of the fully equipped lifeboat when loaded with the number of persons for which the lifeboat is to be approved is applied evenly to the lifeboat falls and over, and is the one determined by the manufacturer.


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(4) It is to be demonstrated that the release mechanism can release the fully equipped lifeboat when loaded with weights equal to the mass of the number of persons for which the lifeboat is to be approved, when the lifeboat is being towed at speeds up to 5 knots. In lieu of a waterborne test, this test may be conducted as follows : (a) a force equal to the force necessary to tow the lifeboat at a speed of 5 knots is to be applied to the hook in

the lengthwise direction of the boat at an angle of 45°to the vertical. This test is to be conducted in the aftward as well as the forward direction, depending upon the design of the release hook;

(b) a force equal to the safe working load of the release mechanism is to be applied to the hook in an athwartships direction at an angle of 20°to the vertical. This test is to be conducted on both port and starboard sides;

(c) a force equal to the safe working load of the release mechanism is to be applied to the hook in a direction half-way between the positions of (a) and (b) and within the ellipse segment formed by (a) and (b). This test is to be conducted in four positions.

2 Free-fall Lifeboats [6.10.5～6.10.6] (1) It is to be demonstrated that the free-fall release mechanism can operate effectively when loaded with a force

equal to at least 200% of the normal load caused by the fully equipped lifeboat when loaded with the number of persons for which it is to be approved.

(2) The release mechanism is to be mounted on a tensile strength testing device. The load is to be increased to at least six times the safe working load of the release mechanism without failure of the release mechanism.

1.2.10 Lifeboat Operation Test [6.11] 1 Operation of Engine and Fuel Consumption Test [6.11.1]

The lifeboat is to be loaded with weights equal to the mass of its equipment and the number of persons for which the lifeboat is to be approved. The engine is to be started and the lifeboat manoeuvred for a period of at least 4 hours to demonstrate satisfactory operation. It is to be demonstrated during the 4 hours operation that ahead/astern, turning and steering performances are satisfactory and that the lifeboat can run ahead at least at 6 knots with its auxiliary machinery being in operation and has the required fuel tank capacity after the lifeboat has been run at a speed of not less than 6 knots for a period which is sufficient to ascertain the fuel consumption. It is also to be demonstrated that the lifeboat can tow a 25-person liferaft loaded with the number of persons for which it is to be approved and its equipment at a speed of 2 knots. 2 Compass [6.11.7]

It is to be determined that the compass performance is satisfactory and that it is not unduly affected by magnetic fittings and equipment in the lifeboat.

1.2.11 Lifeboat Towing and Painter Release Test [6.12] 1 Towing Test [6.12.1]

It is to be demonstrated that the fully equipped lifeboat, loaded with a properly distributed mass equal to the mass of the number of persons for which it is to be approved, can be towed at a speed of not less than 5 knots in calm water and on an even keel. There are to be no damage to the lifeboat or its equipment as a result of this test. 2 Davit-launched Lifeboat Painter Release Test [6.12.2] (1) It is to be demonstrated that the painter release mechanism can release the painter on a fully equipped and

loaded lifeboat that is being towed at a speed of not less than 5 knots in calm water. (2) The painter release mechanism is to be tested in several distinct directions of the upper hemisphere not

obstructed by the canopy or other constructions in the lifeboat. The directions specified in 1.2.9-1(4) is to be used if possible.

1.2.12 Other Performance Tests 1 Retrieval test (1) Lifting of Persons from Water

It is to be demonstrated that an exhausted person in water can be easily brought into the lifeboat by two lifeboat crew. To enable the lifeboat crew not to easily lift the person from water, he is to have his back to the crew, and all members are to wear lifejackets of an approved type.

(2) Bringing of Stretchers into the Lifeboats The lifeboat is to be placed on the test bed. It is then to be demonstrated that a stretcher with a person is to be

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brought into the lifeboat without difficulties. 2 Emergency Steering Test

It is to be demonstrated that for a lifeboat fitted with a remote steering mechanism, a change over is possible without difficulties from steering by the remote steering mechanism to steering by the tiller. 3 Watertightness Test of Battery Casings

Casings covering the batteries are to be filled with water and are to show no sign of water leakage. 4 Charging Test

Batteries used for engine starting and for supplying to the search light are to be tested to be re-chargeable. 5 Rowing Test for Davit-launched Lifeboats

It is to be possible for the davit-launched lifeboat to be capable of being rowed without difficulties. 6 Test for Bailing Means

A test is to be carried out to ascertain effectiveness of the bailing means.

1.2.13 Additional Test for Partially Enclosed Lifeboats 1 Canopy Erection Test [6.14.1, 6.14.2] (1) During the test the lifeboat is to be loaded with the number of persons for which it is to be approved. (2) It is to be demonstrated that the canopy can be easily erected by not more than two persons.

1.2.14 Additional Tests for Self-righting Partially Enclosed Lifeboats 1 Canopy Erection Test [6.14.1, 6.14.3] (1) During the test the lifeboat is to be loaded with the number of persons for which it is to be approved. (2) It is to be demonstrated that the canopy can be easily erected by not more than two persons in two min or less. 2 Self-righting Test [6.15.1, 6.15.2] (1) A suitable means is to be provided to rotate the lifeboat about a longitudinal axis to any angle of heel and then

release it. The lifeboat, in the enclosed condition, is to be incrementally rotated to angles of heel up to and including 180°and is to be released. After release, the lifeboat is always to return to the upright position without the assistance of the occupants. These tests are to be conducted in the following conditions of load : (a) when the lifeboat with its engine is loaded in the normal position with properly secured weights

representing the fully equipped lifeboat with a full complement of persons on board. The weight used to represent each person, assumed to have an average mass of 75 kg, is to be secured at each seat location and have its centre of gravity approximately 300 mm above the seatpan; and

(b) when the lifeboat is loaded with the weight referred to in (a) above, but without the weight representing a full complement of persons on board.

(2) At the beginning of these tests, the engine is to be running in neutral position and : (a) unless arranged to stop automatically when inverted, the engine is to continue to run when inverted and for

30 min after the lifeboat has returned to the upright position; (b) if the engine is arranged to stop automatically when inverted, it is to be easily restarted (in the case of a

self-righting partially enclosed lifeboat after the water has drained from the lifeboat) and run for 30 min after the lifeboat has returned to the upright position.

3 Flooded Capsizing Test [6.15.3～6.15.5] (1) The lifeboat is to be placed in the water and fully flooded until the lifeboat can contain no additional water. All

entrances and openings are to be secured to remain open during the test. (2) For the purpose of this test, the mass and distribution of the occupants may be disregarded. However, the

equipment, or equivalent mass, is to be secured in the lifeboat in the normal operating position. (3) Using a suitable means, the lifeboat is to be rotated about a longitudinal axis to a heel angle of 180°and then

released. After release, the lifeboat is to attain a position that provides an above-water escape for the occupants. 4 Strength and Holding Tests for Safety Belts [Reg. 43-3.1, 44-3.1]

The test is to be carried out either by making the lifeboat incline 180°with a 100 kg dummy held by a safety belt attached to a seat or by simulating the same effect : (1) No defect is to be found in the strengths of seats and safety belts, and (2) the dummy is to be secured.


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1.2.15 Additional Tests for Totally Enclosed Lifeboats 1 Application of Tests Required for Self-righting Partially Enclosed Lifeboats [6.15]

Self-righting test as specified in 1.2.14-2, flooded capsizing test as specified in 1.2.14-3 and strength and holding tests for safety belts as specified in 1.2.14-4 are to apply. 2 Atmospheric pressure holding test

If the lifeboat is provided with the engine which uses the air within the enclosure, all entrances and openings, with the exception of the air ventilators, of the lifeboat are to be closed, and the engine is to run at rated speed until such time as the atmospheric pressure within the enclosure becomes constant. The internal atmospheric pressure is not to fall below the outside atmospheric pressure by more than 20 hPa. 3 Watertightness test for hatches

Hatches are to be tested for watertightness. The test may be conducted by ascertaining the contact conditions of the hatches.

1.2.16 Additional Tests for Lifeboats with a Self-contained Air Support System [6.16] 1 Application of Tests Required for Totally Enclosed Lifeboats

Tests required for the totally enclosed lifeboat as specified in 1.2.15 are to apply. 2 Air supply test

All entrances and openings of the lifeboat are to be closed, the air supply to the inside of the lifeboat turned on and the engine run at full speed for a period of 10 min. During this time the atmospheric pressure within the enclosure is to be continuously measured to ascertain that a small positive air pressure is maintained within the lifeboat and to confirm that noxious gases cannot enter. Even if the engine should stop, the internal air pressure must never fall below the outside atmospheric pressure nor must it exceed outside atmospheric pressure by more than 20 hPa during the test. It is to be ascertained that when the air supply is depleted automatic means are to be activated to prevent the internal air pressure from falling more than 20 hPa.

1.2.17 Additional Tests for Fire-protected Lifeboats [6.17] 1 Application of Tests Required for Lifeboats with a Self-contained Air Support System

Tests required for lifeboats with a self-contained air support system as specified in 1.2.16 is to apply. 2 Fire Test [6.17.1～6.17.7] (1)

(a) The lifeboat is to be moored in the centre of the area which is not less than five times the maximum projected plan area of the lifeboat and which is surrounded by divisions to prevent any leakage of kerosene for the fire test. Sufficient kerosene is to be floated on the water within the area so that when ignited it will sustain a fire which completely envelops the lifeboat for the period of time specified in (c).

(b) The engine is to be run at full speed; however, the propeller need not be turning. The gas- and fire-protective systems are to be in operation throughout the fire test.

(c) The kerosene is to be ignited. It is to continue to burn and envelop the lifeboat for 8 min. (2)

(a) During the fire test, the temperature is to be measured and recorded as a minimum at the following locations : i) at not less than 10 positions on the inside surface of the lifeboat; ii) at not less than five positions inside the lifeboat at locations normally taken by occupants and away

from the inside surface; and iii) on the external surface of the lifeboat.

The positions of such temperature recorders are to be to the satisfaction of the Society. The method of temperature measurement is to allow the maximum temperature to be recorded.

(b) The atmosphere inside the lifeboat is to be continuously sampled and representative retained samples are to be analysed for the presence and quantity of essential, toxic, and injurious gases or substances. The analysis is to cover the range of anticipated gases or substances that may be produced and which can vary according to the materials and fabrication techniques used to manufacture the lifeboat.

(c) The pressure inside the lifeboat is to be continuously recorded to confirm that a positive pressure is being maintained inside the lifeboat.

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(3) At the conclusion of the fire test, the condition of the lifeboat is to be such that it could continue to be used in the fully-loaded condition.

(4) The fire test may be waived for any totally enclosed lifeboat provided that the lifeboat differs in size from, but is identical in construction to and retains essentially the same form as another lifeboat which has successfully completed the fire test, that the lifeboat has the protective system as effective as that of the lifeboat tested, and that the water delivery rate and film thickness at various locations around the hull and canopy of the lifeboat are equal to or exceed the measurements made on the lifeboat tested.

3 Water Spray Test [6.17.8～6.17.10] (1) Start the engine and the spray pump. With the engine running at its designed output, the following are to be

measured to obtain the rated value and speed of the pump : (a) the rpm of the engine and the pump; (b) the pressure at the suction and delivery side of the pump.

(2) With the lifeboat in an upright position, on an even keel and in the fully loaded condition with the exception of the weights equal to the number of the persons for which the lifeboat is to be approved, run the pump at the rated speed. Measure the delivery rate of water or the thickness of the sprayed water film at the external surface of the lifeboat. The delivery rate of water or the sprayed water film thickness over the lifeboat is to be to the satisfaction of the Society.

(3) Successively trim the lifeboat 5°by the head and 5°by the stern, and heel it 5°to port and 5°to starboard. In each condition the sprayed water film is to cover the whole surface of the lifeboat.

1.2.18 Measuring and Evaluating Acceleration Forces [6.18] 1 Selection, Placement and Mounting of Accelerometers [6.18.1～6.18.5] (1) The accelerometers used to measure the acceleration forces in the lifeboat are :

(a) to have adequate frequency response for the test in which they are to be used but the frequency response are to be at least in the range of 0 to 200 Hz;

(b) to have adequate capacity for the acceleration forces that will occur during the tests; (c) to have an accuracy of ±5%.

(2) Accelerometers are to be placed in the lifeboat, parallel to the principal axes of the lifeboat, at those locations necessary to determine the worst occupant exposure to acceleration.

(3) The accelerometers are to be mounted on a rigid part of the interior of the lifeboat in a manner to minimize vibration and slipping.

(4) A sufficient number of accelerometers is to be used at each location at which acceleration forces are measured so that all likely acceleration forces at that location can be measured.

(5) The selection, placement, and mounting of the accelerometers are to be to the satisfaction of the Society. 2 Recording Method and Rate [6.18.6～6.18.8] (1) The measured acceleration forces may be recorded on magnetic media as either an analog or a digital signal or a

paper plot of the acceleration signal may be produced. (2) If the acceleration forces are to be recorded and stored as a digital signal, the sampling rate is to be at least 500

samples per second. (3) Whenever an analog acceleration signal is converted to a digital signal, the sampling rate is to be at least 500

samples per second. 3 Evaluation with the Dynamic Response Model [6.18.9～6.18.12] (1) The dynamic response model is the preferred method to evaluate potential for the occupant in a lifeboat to be

injured by exposure to acceleration forces. In the dynamic response model, the human body is idealized as a single-degree-of-freedom spring-mass acting in each co-ordinate direction as shown in Fig. 1. The response of the body mass relative to the seat support, which is excited by the measured accelerations, can be evaluated using a procedure acceptable to the Society. The parameters to be used in the analysis are shown in Table 1 for each co-ordinate direction.

(2) Before performing the dynamic response analysis, the measured accelerations are to be oriented to the primary axes of the seat.

(3) The desired outcome from the dynamic response analysis is the displacement time-history of the body mass relative to the seat support in each co-ordinate direction.


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(4) At all times, the following expression is to be satisfied :

1222

≤⎟⎟⎠

⎞⎜⎜⎝

⎛+⎟

⎟⎠

⎞⎜⎜⎝

⎛+⎟⎟

⎠

⎞⎜⎜⎝

⎛

z

z

y

y

x

x

Sd

Sd

Sd

where xd , yd , and zd are the concurrent relative displacements of body mass with respect to the seat support, in the x, y, and z body axis, as computed from the dynamic response analysis and xS , yS , and zS are relative

displacements which are presented in Table 2 for the appropriate launch condition. 4 Evaluation Using the SRSS (Square Root Sum of the Squares) Method [6.18.13～6.18.17] (1) In lieu of the procedure in 1.2.18-3(1) to (4), the potential for an occupant in a lifeboat to become injured by an

acceleration can be evaluated using the procedure presented in this section. (2) Before performing the SRSS analysis, the measured accelerations are to be oriented to the primary axes of the

seat. (3) Full-scale acceleration data are to be filtered with no less than the equivalent of a 20 Hz low-pass filter. Any

filtering procedure acceptable to the Society may be used. (4) Acceleration data measured on a model are to be filtered with a low-pass filter having a frequency not less than

that obtained with the following expression :

prototypeLL

fmodel

model20

=

where modelf is the frequency of the filter to be used, modelL is the length of the model lifeboat, and prototypeL

is the length of the prototype lifeboat. (5) At all times, the following expression is to be satisfied :

1222

≤⎟⎟⎠

⎞⎜⎜⎝

⎛+⎟

⎟⎠

⎞⎜⎜⎝

⎛+⎟⎟

⎠

⎞⎜⎜⎝

⎛

z

z

y

y

x

x

Gg

Gg

Gg

where xg , yg , and zg are the concurrent accelerations in the x, y and z seat axes and xG , yG and zG are

allowable accelerations which are presented in Table 3 for the appropriate launch condition.

Fig. 1 Independent Single-Degree-Of-Freedom Representation of Human Body

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Table 1 Parameters of the Dynamic Response Model Co-ordinate axis Natural frequency (rad/s) Damping ratio

x 62.8 100 y 58.0 0.090 z 52.9 0.224

Table 2 Suggested Displacement Limits for Lifeboats Acceleration direction Displacement (cm)

Training Emergency ＋X …… Eyeballs in 6.96 8.71 －X …… Eyeballs out 6.96 8.71 ＋Y …… Eyeballs right 4.09 4.95 －Y …… Eyeballs left 4.09 4.95 ＋Z …… Eyeballs down 5.33 6.33 －Z …… Eyeballs up 3.15 4.22

Table 3 SRSS Acceleration Limits for Lifeboats Acceleration direction Displacement (cm)

Training Emergency ＋X …… Eyeballs in 15.0 18.0 －X …… Eyeballs out 15.0 18.0 ＋Y …… Eyeballs right 7.0 7.0 －Y …… Eyeballs left 7.0 7.0 ＋Z …… Eyeballs down 7.0 7.0 －Z …… Eyeballs up 7.0 7.0


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Chapter 2 PROCEDURES FOR PRODUCTION TESTS OF LIFEBOATS


2.1.1 Performance Test of Release Mechanisms of Davit Launched Lifeboats [5.3.1] The test is to be in accordance with 1.2.9-1(1) and (2).

2.1.2 Operation Test [5.3.3] The lifeboat is to be operated for at least 2 hours. During the operation test, it is to be ascertained that the whole system works.

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Annex 2 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL AND PRODUCTION TESTS FOR RESCUE BOATS

Chapter 1 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL OF RESCUE BOATS

1.1 Material Test

1.1.1 Material Test for Rigid Rescue Boats 1 Material Test for Boat Hulls and Rigid Covers [7.1.1, 6.2.1]

The material test is to be in accordance with 1.1.1 “Material Test for Boat Hulls and Rigid Covers” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 2 Material Test for Buoyant Materials [7.1.1, 6.2.1～6.2.7]

The material test is to be in accordance with 1.1.2 “Material Test for Buoyant Materials” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

1.1.2 Material Test for Inflated Rescue Boats 1 Material Test for Materials Used in the Hull Construction [7.2.17]

The materials used in the hull construction of inflated rescue boats are to be subjected to the following tests. If there are any difficulties in conducting the tests in accordance with the following, other test methods deemed to be equivalent may be acceptable. (1) Mass Measurement

Take three test specimens of 100 mm×100 mm, measure mass, and convert the measurements into mass per 1 square metre. The mass per 1 square metre is to be as given in the specification.

(2) Tensile Strength Test Take five each 50 mm wide and 300 mm long test specimens in both warp and weft, grip each test specimen with a gripping distance of 200 mm, and subject it to a tensile test at a speed of 150 to 300 mm/min to measure breaking strength and elongation: (a) breaking strength is to be 1962 N/5cm or more; (b) elongation is to be less than 35%.

(3) Tear Strength Test Take five each 75 mm wide and 300 mm long test specimens in both warp and weft, with a 75 mm notch normal to the longer side at the mid length of the shorter side, subject each test specimen to a tensile speed of 150 mm to 300 mm to measure the maximum load when it tears. The maximum load is to be 39.3 N no more.

(4) Heat Resistance Test Take three test specimens of 150 mm×150 mm, leave them in a thermostatic chamber at a temperature of 130± 2 for one hour, then take them out of the chamber, fold them quickly with hand through 180 o and check for abnormalities. No abnormalities such as adhesion are to be caused.

(5) Cold Resistance Test Take three test specimens of 150 mm×150 mm, leave them in a thermostatic chamber at a temperature of -30 (+0, -5) for one hour, then take them out of the chamber, fold them quickly with hand through 180 o and check for abnormalities. No abnormalities such as cracking are to be caused.

(6) Heat Aging Test Take three test specimens of 150 mm×150 mm in both warp and weft, leave them in the Gear testing equipment (JIS K 6301) at a temperature of 70± 2 for 72 hours, then take them out of the testing equipment and check for abnormalities. No abnormalities such as hardening are to be caused.

(7) Weathering Test


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Take five each 50 mm wide and 500 mm long test specimens in both warp and weft, subject them to accelerated exposure tests for 30 hours during which period water is to be sprayed through a nozzle for 18 minutes at intervals of two hours, and then subject each test specimen to a tensile strength test with a gripping distance of 200 mm, at a tensile speed of 150 mm to 300 mm to measure breaking strength. The tensile strength is to be 90% or more of the original strength.

(8) Flex Cracking Test Take five each 25 mm wide and 300 mm long test specimens in both warp and weft, subject each test specimen to flex motions using a Scott flex cracking testing equipment (JIS K 6328) with a gripping distance of 30 mm, a load of 9.81 N, a speed of 120 cycles per minute, and a stroke of 50 mm for 500 cycles, and then subject the test specimen to the tensile strength test (2). The breaking strength is to be 90% or more of the original strength.

(9) Coating Adhesion Test Take two 20 mm wide and 200 mm long test specimens with the longer side in parallel with weft, from a rubber-lined texture of a buoyancy chamber. Take two each test specimens in parallel with warp in the same procedure, and subject the test specimens to the following tests: (a) force to detach by hand the rubber layer from texture layer, or a texture layer from another texture layer, of

the test specimen for approximately 30 mm; (b) subject each test specimen to a tensile speed of 50 mm± 2.5 mm/min with a peeling angle of 180 o , and

draw graphs when the test specimen peels off; (c) calculate adhesion strength by the following equation and make the mean value of the test results of two

specimens as the mean test value; bFT f /=

where fT :adhesion strength (N/cm)

F :peeling load (N) b :width of test specimen (cm)

(Note) 1 When difficulties are experienced in peeling operation due to thin or weak rubber layer in preparing

test specimens, apply a rubber layer taken from another rubber lined texture onto the rubber surface of the test specimen using adhesive.

2 When rubber tears off instead of peeling during a test, the test is to be carried on by cutting a notch in the texture with a knife. The highest peak of five peaks (numerical height) is to be taken as a peeling load. The mean adhesion strength is to be 14.7 N/cm or more.

(10) Oil Resistance Test Take three test specimens of 150 mm×150 mm, each with a bonded lap joint by 25 mm at the centre, leave them in gasoline for 24 hours, take them out, and fold them quickly with hand through 180 o and check for abnormalities. No abnormalities such as adhesion are to be caused.

(11) Piercing Strength Test Pierce a pan head nail N90 to a buoyancy chamber of a rescue boat, which has been inflated completely, or to the textile of an simulated buoyancy chamber (JIS A 5508): (a) No sharp pressure drop is caused when the nail pierces through; (b) No rupture or cracking is to be caused from the pierced point immediately after pulling off the nail.

(12) Ozone Resistance Test Take three test specimens, put them in an ozone tester (JIS K 6301), keeping ozone concentration at 50 pphm± 5 pphm, a temperature of 30± 2 for one hour and check for abnormalities. No abnormalities such as cracking are to be caused.

(13) Gas Permeability Test Take three circular test specimens with a diameter of 150 mm and measure hydrogen permeability using a gas permeability tester (JIS K 6328 ). Hydrogen gas permeability is to be 3 l/m2 per 24 hours or less.

(14) Seam Strength Test Take five 50 mm wide and 300 mm long test specimens in both warp and weft, each with a bonded lap joint by 25 mm at the centre, subject each test specimen to a tensile speed of 150 mm to 300 mm with a gripping distance

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of 200 mm, and check for failures. No fractures are to be caused in areas other than the bonded portion. (15) Ultraviolet Light Resistance Test

Take three test specimens of 50 mm×50 mm, apply ultraviolet rays for one hour using the ultraviolet fademeter or equivalent, and check surface hue. No significant discoloration is to be caused.

1.1.3 Material Test for Combined Rescue Boats The material test is to be in accordance with 1.1.1 “Material Test for Rigid Rescue Boats” and 1.1.2 “Material Test for Inflated Rescue Boats”.


1.2.1 Rigid Rescue Boats [7.1] 1 Launch Test [7.1.1]

A launch test is to be carried out in accordance with 1.2.2 “Launch Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 2 Overload Test [7.1.1]

An overload test is to be carried out in accordance with 1.2.3-1 “Lifeboat Overload Test - Davit-launched Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 3 Impact and Drop Tests [7.1.1]

Impact and drop tests are to be carried out in accordance with 1.2.4 “Davit-launched Lifeboat Impact and Drop Test”, with the exception of 1.2.4-1(2), of Annex 1 “Procedures for Prototype Tests for Type approval and Production Tests of Lifeboats”. 4 Seating Strength Test [7.1.1]

A seating strength test is to be carried out in accordance with 1.2.6-1 “Lifeboat Seating Strength Test - Davit-launched Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 5 Seating Space Test [7.1.3]

The rigid rescue boat is to be fitted with its engine and all its equipment. The number of persons for which the rescue boat is to be approved, having an average mass of at least 75 kg and all wearing lifejackets and any other essential equipment required, is then to board; one person is to lie down and the others are to be properly seated in the rescue boat. The rigid rescue boat is then to be manoeuvred and all equipment on board tested to demonstrate that it can be operated without difficulty or interference with the occupants. 6 Non-skid Finish Inspection [7.1.1]

A non-skid finish inspection is to be carried out in accordance with 1.2.7-2 “Lifeboat Seating Space Test - Non-skid Finish Inspection” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 7 Freeboard and Stability Tests [7.1.1]

Freeboard and stability tests are to be carried out in accordance with 1.2.2-8(1)(b) “Loading Test (Freeboard Measurement)” as well as 1.2.8 “Lifeboat Freeboard and Stability Tests” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 8 Release Mechanism Test [7.1.1]

A release mechanism test is to be carried out in accordance with 1.2.9-1 “Release Mechanism Test - Davit-launched Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 9 Operation Test [7.1.1, 7.1.2]

An operation test is to be carried out in accordance with 1.2.10 “Lifeboat Operation Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. It is also to include a test to determine the largest size of fully loaded liferaft which the rigid rescue boat can tow at a speed of at least 2 knots. 10 Towing and Painter Release Test [7.1.1]

A towing and painter release test is to be carried out in accordance with 1.2.11 “Lifeboat Towing and Painter Release Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 11 Other Performance Tests [Reg. 41-3.4]


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(1) Retrieval Test A retrieval test is to be carried out in accordance with 1.2.12-1 “Other Performance Test - Retrieval Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(2) Emergency Steering Test [Reg. 41-7.2] An emergency steering test is to be carried out in accordance with 1.2.12-2 “Other Performance Test - Emergency Steering Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(3) Watertightness Test of Battery Casings [Reg. 41-6.9] A battery casing watertightness test is to be carried out in accordance with 1.2.12-3 “Other Performance Test - Watertightness Test of Battery Casings” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(4) Charging Test [Reg. 41-6.11] A charging test is to be carried out in accordance with 1.2.12-4 “Other Performance Test - Charging Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(5) Test for Bailing Means [Reg. 41-7.12] A test for ascertaining effectiveness of bailing means is to be carried out in accordance with 1.2.12-6 “Other Performance Test - Test for Bailing Means” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

1.2.2 Inflated Rescue Boats [7.2] 1 Launch Test [7.2.1]

A launch test is to be carried out in accordance with 1.2.2 “Launch Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 2 Overload Test [7.2.15, 7.2.16] (1) The inflated rescue boat is to be loaded with four times the mass of the full complement of persons and

equipment for which it is to be approved and suspended from its bridle at an ambient temperature of +20± 3 with all relief valves inoperative for 5 min. The rescue boat and bridle are to be examined after the test is conducted and are to show no signs of damage.

(2) The inflated rescue boat after 6 hours conditioning at a temperature of -30 is to be loaded with 1.1 times the mass of the full complement of persons and equipment for which it is to be approved and suspended from its bridle with all relief valves operative for 5 min. The rescue boat and bridle are to be examined after the test is conducted and are to show no signs of damage.

3 Impact Test [7.2.1] An impact test is to be carried out in accordance with 1.2.4-1 “Davit-launched Lifeboat Impact and Drop Test -

Impact Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. On completion of the impact test, the rescue boat is to show no signs of damage which would affect its efficient functioning. 4 Drop Test [7.2.2, 7.2.3] (1) The inflated rescue boat complete with all its equipment and with a mass equivalent to its engine and fuel in the

position of its engine and fuel tank is to be dropped three times from a height of at least 3 m on to water. The drops are to be from the 45 o bow-down, level-trim and 45 o stern-down attitudes.

(2) On completion of these drop tests, the rescue boat and its equipment are to be carefully examined and show no signs of damage which would affect their efficient functioning.

5 Seating Strength Test [7.2.1] A seating strength test is to be carried out in accordance with 1.2.6-1 “Lifeboat Seating Strength Test -

Davit-launched Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 6 Seating Space Test [7.2.1]

A seating space test is to be carried out in accordance with 1.2.1-5 “Seating Space Test”. 7 Non-skid Finish Inspection [7.2.1]

A non-skid finish inspection test is to be carried out in accordance with 1.2.7-2 “Lifeboat Seating Space Test - Non-skid Finish Inspection” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of

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Lifeboats”. 8 Loading Test (Freeboard Measurement) [7.2.4, 7.2.5] (1) The freeboard of the inflated rescue boat is to be taken in the various loading conditions as follows:

(a) rescue boat with all its equipment; (b) rescue boat with all its equipment, engine and fuel, or an equivalent mass positioned to represent engine

and fuel; (c) rescue boat with all its equipment and the number of persons for which it is to be approved having an

average mass of 75 kg so arranged that a uniform freeboard is achieved at the side buoyancy tubes; and (d) rescue boat with the number of persons for which it is to be approved and all its equipment, engine and fuel

or an equivalent mass to represent engine and fuel and the rescue boat being retrimmed as necessary. (2) With the rescue boat in any of the conditions prescribed in (1), the minimum freeboard is to be not less than 300

mm at the buoyancy tubes and not less than 250 mm from the lowest part of the transom. 9 Stability Test [7.2.6, 7.2.7] (1) The following tests are to be carried out with engine and fuel or an equivalent mass in place of the engine and

fuel tanks: (a) the number of persons for which the inflated rescue boat is to be approved is to be crowded to one side with

half this complement seated on the buoyancy tube, and then to one end. In each case the freeboard is to be recorded. Under these conditions the freeboard is to be everywhere positive; and

(b) the stability of the rescue boat during boarding is to be ascertained by two persons in the rescue boat demonstrating that they can readily assist from the water a third person who is required to feign unconsciousness. The third person is to have his back towards the side of the rescue boat so that he cannot assist the rescuers. All persons are to wear approved lifejackets.

(2) These stability tests may be carried out with the rescue boat floating in still water. 10 Damage Test [7.2.8] (1) The following tests are to be carried out with the inflated rescue boat loaded with the number of persons for

which it is to be approved both with and without engine and fuel or an equivalent mass in the position of the engine and fuel tank: (a) with forward buoyancy compartment deflated; (b) with the entire buoyancy on one side of the rescue boat deflated; and (c) with the entire buoyancy on one side and the bow compartment deflated.

(2) In each of the conditions prescribed by (1), the full number of persons for which the rescue boat is to be approved is to be supported within the rescue boat.

11 Swamp Test [7.2.14] It is to be demonstrated that the rescue boat, when fully swamped, is capable of supporting its full equipment, the

number of persons for which it is to be approved and a mass equivalent to its engine and full tank. It is also to be demonstrated that the rescue boat does not seriously deform in this condition. 12 Release Mechanism Test [7.2.1]

A release mechanism test is to be carried out in accordance with 1.2.9-1 “Release Mechanism Test - Davit-launched Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 13 Operation Test [7.2.1]

An operation test is to be carried out in accordance with 1.2.10 “Lifeboat Operation Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 14 Manoeuvrability and Towing Tests [7.2.10, 7.2.11] (1) It is to be demonstrated that the inflated rescue boat can be propelled and manoeuvred by its oars or paddles in

calm water conditions at a speed of at least 0.5 knots over a distance of at least 25 m, when laden with the number of persons, all wearing lifejackets, for which it is to be approved.

(2) Speed and manoeuvring trials are to be carried out with engines of various powers to assess the rescue boat’s performance.

15 Towing and Painter Release Test [7.2.1] A towing and painter release test is to be carried out in accordance with 1.2.11 “Lifeboat Towing and Painter

Release Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.


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16 Righting Test [7.2.12] It is to be demonstrated that both with and without engine and fuel or an equivalent mass in place of the engine and

fuel tank, the inflated rescue boat is capable of being righted by not more than two persons if it is inverted on the water. 17 Simulated Heavy Weather Test [7.2.13]

To simulate use in heavy weather the inflated rescue boat is to be fitted with a larger powered engine than is intended to be fitted and driven hard in a wind of force 4 or 5 or equivalent rough water for at least 30 min. As a result of this test the rescue boat is not to show undue flexing or permanent strain nor have lost more than minimal pressure. 18 Mooring out Test [7.2.18] (1) The inflated rescue boat is to be loaded with mass equal to the mass of the total number of persons for which it

is to be approved and its equipment and moored in a location at sea or in a seawater harbour. The rescue boat is to remain afloat in that location for 30 days. The pressure of the compartments may be topped up once a day using the manual pump; however, during any 24 hours period the rescue boat is to retain its shape. The rescue boat is not to sustain any damage that would impair its performance. After this test, the rescue boat is to be subjected to the pressure test prescribed in (2) below.

(2) Pressure Test (a) Each inflatable compartment in the rescue boat is to be tested to a pressure equal to three times the working

pressure. Each pressure relief valve is to be made inoperative, compressed air is to be used to inflate the compartments of the rescue boat. The test is to continue for at least 30 min. The pressure is not to decrease by more than 5% as determined without compensating for temperature and atmospheric pressure changes, and there is to be no seam slippage, cracking or other defect in the rescue boat.

(b) The measurement of pressure drop due to leakage is to be started when it has been assumed that compartment rubber material has been completed stretching due to the inflation pressure and stabilized.

19 Other Performance Tests (1) Bringing of Stretchers into the Rescue Boat [Reg. 41-3.4]

A test for bringing of stretchers into the rescue boat is to be carried out in accordance with 1.2.12-1(2) “Other Performance Tests - Retrieval Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(2) Emergency Steering Test [Reg. 41-7.2] An emergency steering test is to be carried out in accordance with 1.2.12-2 “Other Performance Tests - Emergency Steering Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(3) Watertightness Test of Battery Casings [Reg. 41-6.9] A watertightness test of battery casings is to be carried out in accordance with 1.2.12-3 “Other Performance Test - Watertightness Test of Battery Casings” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(4) Charging Test [Reg. 41-6.11] A charging test is to be carried out in accordance with 1.2.12-4 “Other Performance Tests - Charging Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(5) Test for Bailing Means [Reg. 41-7.12] A test for ascertaining effectiveness bailing means is to be carried out in accordance with 1.2.12-6 “Other Performance Test - Test for Bailing Means” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

20 Detailed Inspection [7.2.19] The inflated rescue boat complete in all respects is to be fully inflated in the manufacturer’s works and subjected to

detailed inspection to ensure that all the requirements are fulfilled.

1.2.3 Combined Rescue Boats 1 Launch Test

A launch test is to be carried out in accordance with 1.2.2 “Launch Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

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2 Overload Test An overload test is to be carried out in accordance with 1.2.3-1 “Lifeboat Overload Test - Davit-launched

Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats” and 1.2.2-2 “Inflated Rescue Boats - Overload Test”. 3 Impact Test

An impact test is to be carried out in accordance with 1.2.4-1(1) “Davit-launched Lifeboat Impact and Drop Test - Impact Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. One completion of the test, the rescue boat is not to show any signs of damage which would affect its efficient functioning. 4 Drop Test

A drop test is to be carried out in accordance with 1.2.2-4 “Drop Test”. 5 Seating Strength Test

A seating strength test is to be carried out in accordance with 1.2.6-1 “Lifeboat Seating Strength Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 6 Seating Space Test

A seating space test is to be carried out in accordance with 1.2.1-5 “Seating Space Test”. 7 Non-skid Finish Inspection

A non-skid finish inspection is to be carried out in accordance with 1.2.7-2 “Lifeboat Seating Space Test - Non-skid Finish Inspection” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 8 Loading Test (Freeboard Measurement)

A loading test is to be carried out in accordance with 1.2.2-8 “Inflated Rescue Boats - Loading Test (Freeboard Measurement)”. 9 Stability Test

A stability test is to be carried out in accordance with 1.2.2-9 “Inflated Rescue Boats - Stability Test”. 10 Damage Test

A damage test is to be carried out in accordance with 1.2.2-10 “Inflated Rescue Boats - Damage Test”. 11 Swamp Test

A swamp test is to be carried out in accordance with 1.2.2-11 “Inflated Rescue Boats - Swamp Test”. 12 Release Mechanism Test

A release mechanism test is to be carried out in accordance with 1.2.9-1 “Release Mechanism Test - Davit-launched Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 13 Operation Test

An operation test is to be carried out in accordance with 1.2.10 “Lifeboat Operation Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 14 Manoeuvrability and Towing Tests

A manoeuvrability and towing test is to be carried out in accordance with 1.2.2-14 “Inflated Rescue Boats - Manoeuvrability and Towing Test”. 15 Towing and Painter Release Test

A towing and painter release test is to be carried out in accordance with 1.2.11 “Lifeboat Towing and Painter Release Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”. 16 Righting Test

A righting test is to be carried out in accordance with 1.2.2-16 “Inflated Rescue Boat - Righting Test”. 17 Simulated Heavy Weather Test

A simulated heavy weather test is to be carried out in accordance with 1.2.2-17 “Inflated Rescue Boat - Simulated Heavy Weather Test”. 18 Mooring out Test

A mooring out test is to be carried out in accordance with 1.2.2-18 “Inflated Rescue Boat - Mooring Out Test”. 19 Other Performance Tests (1) Test for Bringing of Stretchers into the Rescue Boats [Reg. 41-3.4]

A test for bringing of stretchers into the rescue boat is to be carried out in accordance with 1.2.12-1(2) “Other


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Performance Tests - Retrieval Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(2) Emergency Steering Test [Reg. 41-7.2] An emergency steering test is to be carried out in accordance with 1.2.12-2 “Other Performance Tests - Emergency Steering Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(3) Watertightness Test of Battery Casings [Reg. 41-6.9] A watertightness test of battery casings is to be carried out in accordance with 1.2.12-3 “Other Performance Tests - Watertightness Test of Battery Casings” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(4) Charging Test [Reg. 41-6.11] A charging test is to be carried out in accordance with 1.2.12-4 “Other Performance Tests - Charging Test” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

(5) Test for Bailing Means [Reg. 41-7.12] A test for ascertaining effectiveness of bailing means is to be carried out in accordance with 1.2.12-6 “Other Performance Tests - Effectiveness Test for Bailing Means” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

20 Detailed Inspection A detailed inspection is to be carried out in accordance with 1.2.2-20 “Inflated Rescue Boats - Detailed

Inspection”.

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Chapter 2 PROCEDURES FOR PRODUCTION TESTS OF RESCUE BOATS


2.1.1 Release Mechanism Test [5.3.1] A release mechanism test is to be carried out in accordance with 1.2.9-1(1), 1.2.9-2(2) “Release Mechanism Test - Davit-launched Lifeboats” of Annex 1 “Procedures for Prototype Tests for Type Approval and Production Tests of Lifeboats”.

2.1.2 Overload, Pressure and Tightness Tests of Inflated and Combined Rescue Boats 1 Overload Test [5.2]

Every inflated rescue boat and every combined rescue boat are to undergo a 10% overload test in accordance with the approved drawings or construction specification before the final pressure and tightness tests in the manner as specified below: (1) the rescue boat is to be inflated with air and stabilized at its working pressure; (2) the working pressure is to be determined by the reseat of the relief valves. The pressure relief valves are to be

fully operational; (3) the rescue boat is to be overloaded by 10% of the mass of the rescue boat assembly together with its full

equipment and complement of persons; (4) the loaded rescue boat is to remain suspended for not less than 5 min; and (5) the rescue boat is not to sustain damage to its suspension members, their attachments, or any other structural

component as a result of this test. The pressure relief valves are to maintain the normal working pressure of the buoyancy tubes and their basic shape during suspension.

2 Pressure and Tightness Tests (1) Pressure Test

The buoyancy chambers of each inflated rescue boat and combined rescue boat are to undergo a pressure test at a pressure of 1.5 times the working pressure. Keeping each relief valve inoperable, inflate the buoyancy chambers with compressed air. The pressure drop in 30 minutes or more is to be 5% or less without making corrections for temperatures and atmospheric air pressure changes, and no damage such as seam displacements, cracking or other failures are to be caused. Measurement of pressure drops are to be started when the rubber material of the buoyancy chamber extends completely due to the inflation pressure to reach a stable condition. After these tests, the relief valve is to be tested for a blowing off pressure and shutting pressure to determine if these pressures are appropriate.

(2) Tightness Test The gas-tightness of the buoyancy chambers of each inflated rescue boat and combined rescue boat is to be tested by inflating them with compressed air to the working pressure. Measure the pressure in 30 minutes, and make adjustments to the working pressure, if necessary. In one hour, the measured pressure drop with corrections made for temperature and atmospheric air pressure changes is not to exceed 5%. Two buoyancy chambers may be tested at one time, but one buoyancy chamber provided with a common pressure boundary is to be kept open to the atmospheric air during the test.

2.1.3 Operation Test [5.3.3] An operation test is to be carried out for at least 2 hours to confirm all system operations.


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Annex 3 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL AND PRODUCTION TESTS OF INFLATABLE LIFERAFTS

Chapter 1 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL OF INFLATABLE LIFERAFTS

1.1 Material Test [5.17.13]

Materials for main buoyancy chambers, canopy supports, floors, floor buoyancy chambers and canopy are to be subjected to the following tests. When there are any difficulties in carrying out these tests, other testing means deemed to be equivalent may be acceptable.

1.1.1 Mass Measurement A mass measurement is to be carried out in accordance with 1.1.2-1(1) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”.

1.1.2 Tensile Strength Test 1 The test procedures are to be in accordance with 1.1.2-1(2) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”: (1) The breaking strength and elongation of the materials for the main buoyancy chambers, canopy supports, floors

and floor buoyancy chambers are to be not less than 1962 N/5cm, and not more than 35%; (2) The breaking strength of the materials for the canopy is to be not less than 491 N/5cm. No required elongation is

specified.

1.1.3 Tear Strength Test 1 The test procedures are to be in accordance with 1.1.2-1(3) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”: (1) The maximum load of the materials for the main buoyancy chambers, canopy supports, floors and floor

buoyancy chambers is to be not less than 39.3 N; (2) The maximum load of the materials for the canopy is to be not less than 9.81 N.

1.1.4 Heat Resistance Test A heat resistance test is to be carried out in accordance with 1.1.2-1(4) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”.

1.1.5 Cold Resistance Test 1 The test procedures are to be in accordance with 1.1.2-1(5) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”. 2 Take three specimens of 150 mm×150 mm from the rubber lined sheets of the main buoyancy chamber, leave specimens in a thermostatic chamber at a temperature of -60 (-5, +0) for 10 minutes, then take them out of the chamber, fold them by hand quickly through 180°and check if there are any abnormalities. No abnormalities such as cracking are to be caused.

1.1.6 Heat Aging Test A heat aging test is to be carried out in accordance with 1.1.2-1(6) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type

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Approval and Production Tests of Rescue Boats”.

1.1.7 Weathering Test A weathering test is to be carried out in accordance with 1.1.2-1(7) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”.

1.1.8 Gas Permeability Test (for Main Buoyancy Chambers, Canopy Supports and Floor Buoyancy Chambers Only)

A gas permeability test is to be carried out in accordance with 1.1.2-1(13) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”.

1.1.9 Water-proofing Test Take three test specimens of 200 mm×200 mm, apply a pressure of 290 kPa to the materials of the main buoyancy chamber and 49 Pa to the material for the canopy sheet using a hydrostatic tester provided with a pressure bearing area of 100 mmφ for 3 minutes, and check for abnormalities. No abnormalities such as rupture and leakage

are to be caused.

1.1.10 Coating Adhesion Test A coating adhesion test is to be carried out in accordance with 1.1.2-1(9) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”.

1.1.11 Oil Resistance Test An oil resistance test is to be carried out in accordance with 1.1.2-1(10) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”.

1.1.12 Flex Cracking Test A flex cracking test is to be carried out in accordance with 1.1.2-1(8) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of Rescue Boats”.

1.1.13 Seam Strength Test A seam strength test is to be carried out in accordance with 1.1.2-1(14) “Material Test for Inflated Rescue Boats - Material Test for Materials Used in the Hull Construction” of Annex 2 “Procedures for Prototype Tests for Type Approval and Production Tests of rescue Boats”.


1.2.1 Drop Test [5.1.1～5.1.4] 1 Each type of liferaft is to be subjected to a minimum of two drop tests. Where the liferaft in its operational condition is packed in a container or valise, one such test is to be carried out with the liferaft packed in each type of container or valise. 2 The liferaft, in the operationally packed condition, is to be dropped from a height of 18 m into the water. If it is to be stowed at a height greater than 18 m, it is to be dropped from the height at which it is to be stowed. The free end of the painter is to be attached to the point of suspension so that it pays out as the liferaft drops, thus simulating actual conditions. 3 The liferaft is to be left floating for 30 min, and then to be inflated. The liferaft is to inflate correctly within 1 min. The test is in principle to be conducted at the normal temperature. If the temperature is extremely low, time required for inflation is to be determined by the Society taking account of the requirement as specified on 1.2.17-3. The liferaft is then to be lifted from the water to permit thorough inspection of the liferaft, the contents of the equipment container and the container or valise. 4 Damage to the container or valise, if the liferaft is normally within it when launched, is acceptable provided the


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Society is satisfied that it would not be a hazard to the liferaft. Damage to any item of equipment is acceptable subject to the Society being satisfied that the operational efficiency has not been impaired. Damage to fresh water receptacles may be accepted provided they do not leak. However, for drop tests from heights exceeding 18 m, leakage from up to 5% of the receptacles may be accepted provided that: (1) the equipment list for the inflatable liferaft specifies the carriage of 5% excess water or means of desalination

adequate to produce an equivalent amount; or (2) the water receptacles are contained in a waterproof overwrap.

1.2.2 Jump Test [5.2] 1 It is to be demonstrated that a person can jump on to the liferaft, with and without the canopy erected, from a height above the floor of at least 4.5 m without damaging the liferaft. The test subject is to weigh not less than 75 kg and is to be wearing hard bottom shoes with smooth soles and no protruding nails. The number of jumps performed is to be equal to the total number of persons for which the liferaft is to be approved. 2 The jump test may be simulated by dropping a suitable and equivalent mass. 3 There is to be no torn fabric, or damage to seams as a result of the test.

1.2.3 Weight Test [5.3] The fully packed liferaft container is to be weighed to determine whether its mass exceeds 185 kg. The weight test is to be performed on the heaviest variation of the liferaft, considering different containers and equipment packs which may be used. If the mass exceeds 185 kg, the different combinations of containers and equipment packs are to be weighed to determine which will and which will not exceed 185 kg.

1.2.4 Towing Test [5.4] It is to be demonstrated by towing that the fully loaded and equipped liferaft is capable of being satisfactorily towed at speeds of up to 3 knots in calm water. Towing is to be by a line attached to the liferaft’s towing connection. The sea anchor is to be streamed while the liferaft is towed. The liferaft is to be towed for a distance of at least 1 km.

1.2.5 Mooring Out Tests [5.5] The liferaft is to be loaded with mass equal to the mass of the total number of persons for which it is to be approved and its equipment and moored in a location at sea or in a seawater harbour. The liferaft is to remain afloat in that location for 30 days. The pressure may be topped up once a day using the manual pump; however, during any 24 hours period the liferaft is to retain its shape. The liferaft is not to sustain any damage that would impair its performance. After this test, the inflatable liferaft is to be subjected to the pressure test prescribed in 1.2.18.

1.2.6 Painter System Test [5.6] The rope to be used as a painter system is to be tensile tested and is to have a breaking strain as follows: (1) 10.0 kN for liferafts to carry nine persons or more; and (2) 7.5 kN for any other liferaft.

1.2.7 Loading and Seating Test (Freeboard Measurement) [5.7] The freeboard of the liferaft loaded with its full equipment but no personnel is to be recorded. The freeboard of the liferaft is again to be recorded when the number of persons for which the liferaft is to be approved, having an average mass of 75 kg, and each wearing a lifejacket, have boarded and are seated. It is to be demonstrated by the liferaft with the floor inflated that all the seated persons have sufficient space and headroom and that the various items of equipment can be used within the liferaft in this condition. The freeboard, when loaded with the mass of the number of persons for which it is to be approved and its equipment, with the liferaft on an even keel and with the floor not inflated, is not to be less than 300 mm.

1.2.8 Light Load Stability Test It is to be confirmed that the liferaft with a few persons on board in wave scale 5 has sufficient stability and does not capsize. Instead of persons, weights of equivalent mass may be used. In case the liferaft is fitted with water pockets and the water pockets are in accordance with the following requirements, the above mentioned tests may be dispensed with: (1) The cross-sectional area of the pockets is to be in the shape of an isosceles triangle with the base of the triangle

attached to the underside of the liferaft;

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(2) The pockets are to be distributed symmetrically round the circumference of the liferaft either side of the CO2 bottle to enable air to escape readily;

(3) The design is to be such that the pockets fill to 60% or more of capacity within 25 seconds of deployment; (4) The number of the pockets and their aggregate capacity are to be in accordance with Table 1.

Table 1 Number of Pockets and Their Aggregate Capacity

Raft capacity (N) Number of pockets Aggregate capacity (liters)

6 - 8 5 or more 225 - 250

9 - 10 7 or more 225 - 250 11 - 16 7 or more 20×N

17 - 25 11 or more 20×N

1.2.9 Boarding Test [5.8] The boarding test is to be carried out in a swimming pool by a team of four persons who are of mature age and of differing physiques, such as those who are tall and slim, tall and fat, medium in height and weight, and small and slim. Preferably they are not to be strong swimmers. For this test they are to be clothed in shirt and trousers or a boiler suit and are to wear approved lifejackets suitable for an adult. They must each swim about 100 m before reaching the liferaft for boarding. There must be no rest period between the swim and the boarding attempt. Boarding is to be attempted by each person individually with no assistance from other swimmers or persons already in the liferaft. The water is to be of a depth sufficient to prevent any external assistance when boarding the liferaft. The arrangements will be considered satisfactory if three of the persons board the liferaft unaided and the fourth boards with the assistance of any of the others.

1.2.10 Stability Test [5.9] 1 The number of persons for which the liferaft is to be approved is to be accommodated on one side and then at one end and in each case the freeboard is to be recorded. Under these conditions the freeboard is to be such that there is no danger of the liferaft being swamped. Each freeboard measurement is to be taken from the waterline to the top surface of the uppermost main buoyancy tube at its lowest point. 2 The stability of the liferaft during boarding may be ascertained as follows : Two persons each wearing approved lifejackets are to board the empty liferaft. It is then to be demonstrated that the two persons in the liferaft can readily assist from the water a third person who is required to feign unconsciousness. The third person must have his back towards the entrance so that he cannot assist the rescuers. It is to be demonstrated that the water pockets adequately counteract the upsetting moment on the liferaft and there is no danger of the liferaft capsizing.

1.2.11 Manoeuvrability Test [5.10] It is to be demonstrated that with the paddles provided, the liferaft is capable of being propelled when fully laden in calm conditions over a distance of at least 25 m.

1.2.12 Swamp Test [5.11] It is to be demonstrated that if the liferaft is fully swamped, it is capable of supporting the number of persons for which it is to be approved and remains seaworthy. The liferaft is not seriously to deform in this condition. The swamped inflatable liferaft is to be tested in at least 10 waves at least 0.3 m high. The waves may be produced by the wake of a boat, or by other acceptable means.

1.2.13 Canopy Closure Test [5.12] To ensure the effectiveness of the canopy closures in preventing water entering the liferaft, the efficiency of the closed entrances is to be demonstrated by means of a hose test or by any other equally effective method. The requirement for the hose test is that about 2,300 of water per minute be directed at and around the entrances through a 63.5 mm hose from a point 3.5 m away and 1.5 m above the level of the buoyancy tubes for a period of 5 min. There is to be no significant accumulation of water inside the liferaft.

1.2.14 Buoyancy of Float-Free Liferafts [5.13] It is to be demonstrated that the liferafts packed in containers which are float-free have sufficient inherent


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buoyancy to inflate the liferaft by means of the actuating line in the event of the ship sinking. The combination of equipment and container or valise is to be that which produces the maximum packed weight.

1.2.15 Damage Test [5.17.1] It is to be demonstrated that, in the event of any one of the buoyancy compartments being damaged or failing to inflate, the intact compartment or compartments is (are) to support, with positive freeboard over the liferaft’s periphery, the number of persons for which the liferaft is to be approved. This can be demonstrated with persons each having a mass of 75 kg and seated in their normal positions or by an equally distributed mass.

1.2.16 Righting Test [5.17.2] For this test the liferaft is to be inverted so as to simulate inverted inflation. (1) The inflatable liferaft is to be loaded with its heaviest equipment pack. All of the entrances, ports, and other

openings in the liferaft canopy are to be open in order to allow the infiltration of water into the canopy when capsized;

(2) The canopy of the liferaft is then to be completely filled with water, if necessary by not inflating a part of the canopy supports. If the inflatable liferaft does not self-right, it is to be allowed to remain in an inverted position for at least 10 min before righting is attempted;

(3) The righting test is to be carried out by the same team of persons required for the boarding test similarly clothed and wearing lifejackets and after completing the swim required in 1.2.9. At least one of the persons righting the inflatable liferaft is to weigh less than 75 kg. Each person is to attempt to right the liferaft unaided. The water is to be of sufficient depth to give no external assistance to the swimmers when mounting the inverted liferaft;

(4) The righting arrangements will be considered satisfactory if each person rights the liferaft unaided. There is to be no damage to the structure of the inflatable liferaft, and the equipment pack is to remain secured in its place.

1.2.17 Inflation Test [5.17.3～5.17.6] 1 A liferaft, packed in each type of container, is to be inflated by pulling the painter and the time recorded: (1) for it to become boardable, i.e. when buoyancy tubes are inflated to full shape and diameter; (2) for the cover to be erect; and (3) for the liferaft to reach its full operational pressure when tested:

(a) at an ambient temperature of between 18 and 20; (b) at a temperature of -30; and (c) at a temperature of +65.

2 When inflated in an ambient temperature of between 18 and 20, it is to achieve total inflation in not more than 1 min. 3 For the inflation test at -30 the packed liferaft is to be kept at room temperature for at least 24 hours, then placed in a refrigerated chamber at a temperature of -30 for 24 hours prior to inflation by pulling the painter. Under these conditions the liferaft is to reach working pressure in 3 min. Two liferafts are to be subjected to an inflation test at this temperature. There is to be no seam slippage, cracking, or other defect in the liferaft and it is to be ready for use after the tests. 4 For the inflation test at +65 the packed liferaft is to be kept at room temperature for at least 24 hours, then placed in a heating chamber at a temperature of +65 for not less than 7 hours prior to inflation by pulling the painter. Under these conditions the gas pressure relief valves must be of sufficient capacity to prevent damage to the liferaft by excess pressure and to prevent the maximum pressure during the inflation from reaching twice the reseat pressure of the release valve. There must be no seam slippage, cracking or other defect in the liferaft.

1.2.18 Pressure Test [5.17.7, 5.17.8] 1 Each inflatable compartment in the liferaft is to be tested to a pressure equal to three times the working pressure. Each pressure relief valve is to be made inoperative, compressed air is to be used to inflate the inflatable liferaft and the inflation source removed. The test is to continue for at least 30 min. The pressure is not to decrease by more than 5% as determined without compensating for temperature and atmospheric pressure changes, and there is to be no seam slippage, cracking or other defect in the liferaft. 2 The measurement of pressure drop due to leakage is to be started when it has been assumed that compartment rubber material has been completed stretching due to the inflation pressure and stabilized.

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1.2.19 Seam Strength Test [5.17.9] It is to be demonstrated that sample seams can withstand a test load equal to the liferaft fabric tensile strength.

1.2.20 Additional Tests for Davit Launched Liferafts 1 Strength Test of Lifting Components [5.16.1]

The breaking strength of the webbing or rope and the attachments to the liferaft used for the lifting bridle is to be established by tests on three separate pieces of each different item. The combined strength of the lifting bridle components is to be at least six times the mass of the liferaft when loaded with the number of persons for which it is to be approved and its equipment. 2 Impact Test [5.16.2]

The liferaft is to be loaded with a mass equal to the mass of the number of persons for which it is to be approved and its equipment. With the liferaft in a free hanging position it is to be pulled laterally to a position so that when released it will strike a rigid vertical surface at a velocity of 3.5 m/s. The liferaft is then to be released to impact against the rigid vertical surface. After this test the liferaft is to show no signs of damage which would affect its efficient functioning. 3 Drop Test [5.16.3]

The liferaft, loaded as prescribed in -2, is to be suspended from an on-load release at a height of 3 m above the water, be released and allowed to fall freely into the water. The liferaft is then to be examined to ensure that no damage has been sustained which would affect its efficient functioning. 4 Boarding Test [5.16.4]

A davit-launched liferaft is, in addition to the boarding test prescribed in 1.2.9, to be subjected to the following test. The liferaft, hanging from a launching appliance and bowsed in to the ship’s side or simulated ship’s side, is to be boarded by the number of persons for which it is to be approved of average mass 75 kg. There is to be no undue distortion of the liferaft. The bowsing is then to be released and the liferaft left hanging for 5 min. It is then to be lowered to the sea or floor and unloaded. At least three tests are required in succession, with the hook of the lowering appliance so positioned that its distance from the ship’s side is:

(1) half the beam of the liferaft +150 mm; (2) half the beam of the liferaft; and (3) half the beam of the liferaft -150 mm.

The boarding, which is intended to simulate actual shipboard conditions, is to be timed and the time recorded. 5 Strength Test [5.17.10～5.7.12] (1) Overload Test at Normal Room Temperature

It is to be demonstrated by an overload test on the liferaft hanging from its centre support that the bridle system has an adequate factor of safety as follows: (a) the liferaft is to be placed in a temperature of 20±3or a period of at least 6 hours; (b) following this period of conditioning, the liferaft is to be suspended from its lifting hook or bridle and the

buoyancy chambers (not including an inflatable floor) inflated; (c) when fully inflated and when the relief valves have reseated themselves, all relief valves are to be made

inoperative; (d) the liferaft is then to be lowered and loaded with a distributed mass equivalent to four times the mass of the

number of persons for which it is to be approved and its equipment, the mass of each person being taken as 75 kg;

(e) the liferaft is then to be raised and remain suspended for at least 5 min; (f) the pressure before and after the test after the weigh is removed and while it remains suspended, is to be

recorded; and (g) any dimensional deflections or distortions of the liferaft are to be recorded. During the test and after its

completion, the inflatable liferaft is to remain suitable for its intended use. (2) Overload Test at Low Temperature

It is to be demonstrated, after a period of 6 hours in a chamber at a temperature of -30, that the liferaft will support a load of 1.1 times the number of persons for which it is to be approved and its equipment with all relief valves operative. The liferaft is to be loaded with the test weight in the refrigerated chamber. The floor is not to be inflated. The loaded inflatable liferaft is to remain suspended for at least 5 min. If the inflatable liferaft must


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be removed from the chamber in order to suspend it, the inflatable liferaft is to be suspended immediately upon removal from the chamber. During the test and after its completion, the inflatable liferaft is to remain suitable for its intended use.

(3) Lowering Test at Ship’s Side The inflatable liferaft is to be loaded with a weight equal to the mass of its heaviest equipment pack and the number of persons for which it is to be approved, the mass of each person being taken as 75 kg. Except for the floor which is not to be inflated, the inflatable liferaft is to be fully inflated with all relief valves operative. A liferaft is to be lowered for a distance of at least 4.5 min continuous contact against a structure erected to represent the side of a ship having a 20°adverse list. During the test and after its completion, the liferaft is not to sustain damage or distortion, or assume a position which would render it unsuitable for its intended purpose.

1.2.21 Other Performance Tests 1 Air-charging test

The air-charging operation is to be performed using air-charging pumps or bellows fitted to the chambers. The pumps or the bellows are to be capable of raising the pressure to the necessary level whenever the pressure in the chambers falls. 2 Automatic lighting test

It is to be confirmed that the external and internal lamps light automatically when the liferaft inflates and are of sufficient intensity to enable any person in the vicinity of the internal lamp to read survival and equipment instructions while seating.

1.2.22 Detailed Inspection [5.14] A liferaft, complete in all respects and in a fully inflated condition, is to be subjected to a detailed inspection in the manufacturer’s works to ensure that all the requirements are fulfilled.

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Chapter 2 PROCEDURES FOR PRODUCTION TESTS OF INFLATABLE LIFERAFTS


2.1.1 Inflation Test [5.1.1～5.1.3] 1 A completed and operationally packed liferaft is to be selected at random, and is to be subjected to an operational inflation test on a smooth dry floor or on water, e.g. a swimming pool, as a check on the packing and inflation. 2 The sampling rate of liferafts to be subjected to the operational inflation test for a period is to be determined by the Society, taking account of the number of liferafts produced for the period, the number of the liferafts to be subjected to the production test and the quality control procedures adopted and implemented. Personnel fabricating and packing inflatable liferafts are not to be made aware of which liferaft will be tested until after the liferaft has been packed in its container. The painter is to be pulled from the liferaft using a device to measure the applied force. The force required to pull the painter and start inflation is not to exceed 150 N. The inflatable liferaft is to break free from its container and attain its design shape and full erection of the canopy support tubes in not more than 1 min. 3 Each liferaft produced is to be inspected for defects and dimensional deviations.

2.1.2 Pressure and Tightness Tests [5.1.4～5.1.6] 1 Pressure Test

Each liferaft produced is to be inflated with air to at least 1.5 times its working pressure. After 30 min the liferaft is not to show signs of seam slippage or rupture, nor is the pressure to decrease by more than 5%. Relief valves are to be inoperative for this test. Following the test, each relief valve is to be tested for proper relief and reseating pressure. 2 Tightness Test (1) The gas-tight integrity of each inflated compartment of each liferaft produced is to be checked by inflating with

air to its working pressure. After a settling time of 30 min the pressure is to be checked and adjusted to the working pressure as necessary. After 1 hour the pressure is not to have decreased by more than 5 % after compensation for temperature and barometric pressure changes. More than one compartment may be tested at one time, but adjacent compartments with common pressure barriers are to be open to the atmosphere during the test.

(2) If the insulation of the floor of the liferaft is obtained by inflation, it is to be inflated to its designed pressure. After a period of 1 hour the pressure is not to have decreased by more than 5% uncorrected pressure change.

2.1.3 10% Overload Test of Davit Launched Liferafts [5.2] Every david-launched liferaft is to undergo a 10% overload test in accordance with the approved drawings or construction specification before the final inflation pressure test in the manner as specified below: (1) the liferaft is to be inflated with air and stabilized at its working pressure; (2) the working pressure is to be determined by the reseat of the relief valves. The pressure relief valves are to be

fully operational; (3) the floor of the inflatable liferaft is not to be inflated; (4) the 10% overload is to be 10% of the mass of the liferaft together with its full equipment and complement of

persons calculated at 75 kg per person; (5) the loaded liferaft is to remain suspended for not less than 5 min; and (6) the inflatable liferaft is not to sustain damage to its suspension members, their attachments, or any other

structural component as a result of this test. The pressure relief valves are to maintain the normal working pressure of the buoyancy tubes and their basic shape during suspension.


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Annex 4 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL AND PRODUCTION TESTS OF LAUNCHING APPLIANCES OF LIFEBOATS,

RESCUE BOATS AND LIFERAFTS

Chapter 1 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL OF LAUNCHING APPLIANCES


1.1.1 Terminology The terminologies used in 1.1 and 2.1 of this Annex 4 are as follows: (1) The maximum working load ( maxL ) of a launching appliance means the maximum load by the total mass of the

following with regard to the lifeboat, rescue boat and liferaft hoisted and lowered by the launching appliance: (a) mass of the fully equipped lifeboat, rescue boat or liferaft; (b) mass of pulleys, ropes, etc.; (c) mass of the number of persons (75 kg per person) for which the lifeboat, rescue boat or liferaft is to be

approved. (2) The minimum working load ( minL ) of a launching appliance means the minimum load by the mass of (1)(a)

above for the lifeboat, rescue boat or liferaft hoisted and lowered by the launching appliance. (3) The maximum hoisting load ( liftL ) of a launching appliance means the maximum load by the mass of (1)(a) and

(b) above with the following for the lifeboat, rescue boat or liferaft hoisted and lowered by the launching appliance. For the lifeboat or liferaft, the mass of two lifeboat or liferaft crew (75 kg per person) is to be added for hoisting the lifeboat or liferaft. For the rescue boat, the mass of six rescue boat crew is to be added for hoisting the rescue boat.

(4) The maximum working load ( maxW ) of a winch means the maximum tension of the hanging rope at the winch

drum when loads are being hoisted, lowered or held. For evaluation of this, friction resistance of pulleys is to be taken into account. In the case of davit launching appliances, the loads when the davits are in the maximum swing out position are also to be taken into account.

1.1.2 Davits and Launching Appliances 1 Overload Test [8.1.1]

For lifeboats other than free-fall lifeboats, davits and launching appliances, except the winch brakes, are to be subjected to a static proof load of 2.2 times their maximum working load ( maxL ). With the load at the full outboard position, the load is to be swung through an arc of approximately 10°to each side of vertical in the intended fore and aft plane. The test is to be done first in the upright position, followed by tests simulating a shipboard condition of list of 20°both inboard and outboard. There is to be no evidence of significant deformation or other damage as a result of this test. For free-fall lifeboats, the launching appliances for lowering a free-fall lifeboat by falls, except the winch brakes, are to be subjected to a static proof load of 2.2 times the maximum working load ( maxL ) at the full outboard

position. There is to be no evidence of significant deformation or other damage as a result of this test. 2 Swing-out Test [8.1.2]

For lifeboats other than free-fall lifeboats, a mass equal to 1.1 times the maximum working load ( maxL ) is to be

suspended from the lifting points with the launching appliance in the upright position. The load is to be moved from the full inboard to the full outboard position using the means of operation that is used on the ship. The test is to be repeated with the launching appliance positioned to simulate a combined 20°inboard list and 10°trim. All the tests are to be repeated with the minimum working load ( minL ) of the appliance to ensure the satisfactory functioning of

the davit under very light load conditions. The appliances are successfully to lower the load under all of the conditions, and there is to be no evidence of significant deformation or other damage as a result of the tests. For

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free-fall lifeboats, a mass equal to 1.1 times the maximum working load ( maxL ) is to be suspended from the lifting

points. The load is to be moved from the full inboard to the full outboard position using the means of operation that is to be used on the ship. The test is to be repeated with the minimum working load ( minL ) of the launching appliance to

ensure the satisfactory functioning of the appliance under light load conditions. The appliance is successfully to lower the load under both conditions and there is to be no evidence of significant deformation or other damage as a result of the tests. 3 Recovery Operation Test [8.1.3]

The maximum designated hoisting load ( liftL ) of the launching appliance is to be suspended from the lifting points

with the launching appliance in the upright position. The appliance is successfully to move the maximum designed hoisting load ( liftL ) from the outboard to the inboard position without causing permanent deformation or other

damage. 4 Break Test [8.1.4]

Winch drums are to be wound to the maximum number of turns permitted and a static test load of 1.5 times the maximum working load ( maxW ) is to be applied and held by the brake. This load is then to be lowered for at least one complete revolution of the barrel shaft. A test load of 1.1 times the maximum working load ( maxW ) is then to be

lowered at maximum lowering speed through a distance of at least 3 m and stopped by applying the hand brake sharply. The test load is to drop no more than 1 m when the brake is applied. This test is to be repeated a number of times. If the winch design incorporates an exposed brake, one of these tests is to be carried out with the brake wetted, but in this case the stopping distance may be exceeded. The various tests are to achieve a cumulative lowering distance of at least 150 m. Operation of the winch with a minimum working load ( minL ) of the launching appliance is

also to be demonstrated. 5 Recovery Operation Test by Rescue Boat Winches [8.1.5]

It is to be demonstrated that a winch intended for use with a rescue boat is capable of recovering the rescue boat with the number of persons for which it is to be approved and its equipment or an equivalent mass at a rate of not less than 0.3 m/s. 6 Hand Operation Test of Winches [8.1.6]

With the exception of winches intended for a free-fall lifeboat, the hand operation of the winch is to be demonstrated. If the winch is designed for quick recovery by hand with no load, this is to be demonstrated with a load of 1.5 times the mass of the empty lifting arrangements. 7 Overhaul Inspection of Winches [8.1.7]

Following completion of the tests the winch is to be stripped for inspection. 8 Pressure Test of Hydraulic Oil Systems

Components of the hydraulic system subject to a pressure of more than 1.6 MPa are to be pressure-tested under a pressure of 1.5 times the designed pressure. 9 Tests for Ramps for Free-Fall Lifeboats

The free-fall test of a full scale model free-fall lifeboat is to be carried out with a launching appliance of the same type as the one used for production free-fall lifeboats in accordance with 1.2.5-1(3) of Annex 1. The results of the test are to meet the acceptance criteris of 1.2.5-2(1)(c) of Annex 1, and in addition, show no risk of incendiary friction or impact sparking during the launching of the lifeboat. 10 Tests for Adjustable Ramps

It is to be demonstrated that adjustable ramps for free-fall launching can be adjusted satisfactorily with the free-fall lifeboat loaded to 1.2 times its related load.


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Chapter 2 PROCEDURES FOR PRODUCTION TESTS OF LAUNCHING APPLIANCES


2.1.1 Launching Appliances Using Falls and Winches 1 Overload Test [6.1.1]

Each launching appliance, except the winch, is to be tested with a static load of 2.2 times the maximum working load with the appliance ( maxL ) in the full outboard position. The appliance is not to be deformed or damaged.

Winches with the brakes applied are to be tested by applying a static load of 1.5 times the maximum working load ( maxW ). Any cast components of the frame and arm are to be hammer-tested to determine that they are sound and

without flaw. 2 Pressure Test of Hydraulic Oil Systems

A pressure test is to be carried out in accordance with 1.1.2-8. 3 Non-destructive Test for Cast Steel Hooks of Launching Appliances for Liferafts [6.2.1]

Cast steel hooks are to be subjected to an approved non-destructive test to confirm that there are no superficial or internal defects.

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Annex 5 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL AND PRODUCTION TESTS OF ENGINES FOR LIFEBOATS AND

RESCUE BOATS

Chapter 1 PROCEDURES FOR PROTOTYPE TESTS FOR TYPE APPROVAL OF ENGINES FOR LIFEBOATS AND RESCUE BOATS

1.1 Performance Test

1.1.1 Internal Combustion Engines for Lifeboats and Rescue Boats (Including Reduction/Reversing Gears) (Excluding Outboard Motors)

1 General Performance Tests (1) Starting Test

When a battery is used for starting the engine, successive starting of six times or more is to be possible when the engine is under normal ambient temperature.

(2) No Load, Low-speed Operation Test The engine is to be subjected to the operation test with no load and with not more than half the maximum continuous rpm for 10 minutes, and it is to be ascertained that the engine runs smoothly.

(3) No Load, High-speed Operation Test This test is to be carried out for an engine not equipped with a governor. Under no load condition, the engine revolution is to be changed from less than half the maximum continuous rpm to not less than 120% of the maximum continuous rpm, and is to be maintained for 10 seconds. The test is to be repeated six times at 10 seconds intervals. Abnormal temperature rise of parts and harmful vibration are not to be present.

(4) Load Test During continuous operating tests under the load and rpm conditions shown in Table 1, measurement of the engine performances and observation of operating conditions are to be carried out

(5) Reverse Operation/Reverse Operating Test The reverse operations of not less than 100 times are to be carried out. Then, the reverse operation test of 0.5 hour is to be performed under the load of 0.75 of the maximum continuous output. Reverse operation is to be free from abnormalities.

(6) Governor Test This test is to be performed for an engine equipped with a governor. During maximum continuous rpm, the load is to be abruptly changed from 100% load to 0%, and the instantaneous speed variation, the time required for stabilization and the speed variation after stabilization are to be recorded. The instantaneous speed variation when the load is changed from 100% to 0% is to be 20% or less.

(7) Charging Test The charging ability is to be confirmed.

(8) Insulation resistance Test The insulation resistance is to be measured by means of a DC 500 V insulation resistance tester. In case, however, apparatus and circuits are not suitable to be tested as above, the test may be dispensed with. The measured insulation resistance is to be 10 ΩM and over.

(9) Endurance Test (a) To ascertain the durability of the engine, the engine is to be subjected to the continuous operation test for 50

hours under conditions of the maximum continuous output and the maximum continuous rpm. Performances and durability are to be free from abnormalities.

(b) The endurance test may be omitted or the period for the endurance test may be shortened when the Society considers it appropriate, taking into consideration the operating experience, or, in case the engine is being


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newly developed, having examined the development records.

Table 1 Loads and Operating Time Load Operating time (Hr) RPM

Max. continuous output×0.25 0.5 RPM is basically to be changed in Max. continuous output×0.50 0.5 proportion to the cubic root ratio of Max. continuous output×0.75 0.5 the load and the max. continuous Max. continuous output×1.00 4.0 output. Max. continuous output×1.10 0.5

2 Cold Engine Starting Tests [6.11.2～6.11.4] (1) The engine may be removed from the lifeboat for this test, however, it is to be equipped with accessories and the

transmission that will be used in the lifeboat. The engine, along with its fuel and coolant, is to be placed in a chamber at a temperature of -15.

(2) The temperature of the fuel, lubricating oil and cooling fluid (if any) is to be measured at the beginning of this test and is not to be higher than -15. Samples of each fluid at this temperature are to be collected in a container for observation.

(3) The engine is to be started three times. The first two times, the engine is to be allowed to operate long enough to demonstrate that it runs at operating speed. After the first two starts the engine is to be allowed to stand until all parts have again reached chamber temperature. After the third start, the engine is to be allowed to continue to run for at least 10 min and during this period the transmission is to be operated through its gear positions without difficulty.

3 Engine-out-of-water Test [6.11.5] The engine is to be operated for at least 5 min at idling speed under conditions simulating normal storage. The

engine is not to be damaged as a result of this test. 4 Submerged Engine Test [6.11.6]

The engine is to be operated for at least 5 min while submerged in water to the level of the centreline of the crankshaft with the engine in a horizontal position. The engine is not to be damaged as a result of this test. 5 Additional Tests for Engines for Self-righting Partially Enclosed Lifeboats, Totally Enclosed Lifeboats, Lifeboats with a Self-Contained Air Support System and Fire-protected Lifeboats (1) Engine Inversion Test [6.15.6～6.15.8]

(a) The engine and its fuel tank are to be mounted on a frame that is arranged to rotate about an axis equivalent to the longitudinal axis of the boat. A pan is to be located under the engine to collect any oil which may leak from the engine so that the quantity of such oil can be measured.

(b) The following procedure is to be followed during this test: i) start the engine and run it at full speed for 5 min; ii) stop the engine and rotate it in a clockwise direction through 360°; iii) restart the engine and run it at full speed for 10 min; iv) stop the engine and rotate it in a counter-clockwise direction through 360°; v) restart the engine, run it at full speed for 10 min, and then stop the engine; vi) allow the engine to cool; vii) restart the engine and run it at full speed for 5 min; viii) rotate the running engine in a clockwise direction through 180°, hold at the 180°position for 10

seconds, and then rotate it 180°further in a clockwise direction to complete one revolution; ix) if the engine is arranged to stop automatically when inverted, restart it; x) allow the engine to continue to run at full speed for 10 min; xi) shut the engine down and allow it to cool; xii) repeat the procedure in vii) through xi), except that the engine is to be turned in a counter-clockwise

direction; xiii) restart the engine and run it at full speed for 5 min; xiv) rotate the engine in a clockwise direction through 180°and stop the engine. Rotate it 180°further to

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complete a full clockwise revolution; xv) restart the engine and run it at full speed for 10 min; xvi) repeat the procedure in xiv), turning the engine counter-clockwise; and xvii) restart the engine, run it at full speed for 10 min and then shut it down.

(c) During these tests, the engine is not to overheat, fail to operate or leak more than 250 ml of oil during any one inversion.

6 Overhaul Inspection [6.15.8] After the tests 1.1.1-1 to 1.1.1-5, the engine is to be dismantled for examination. The engine is to show no evidence

of overheating or excessive wear.

1.1.2 Outboard Motors for Rescue Boats 1 General Performance Tests (1) Starting Test

The start test is to be carried out in accordance with 1.1.1-1(1). (2) No Load, Low-speed Operating Test

The test is to be carried out in accordance with 1.1.1-1(2). (3) No Load, High-speed Test

The test is to be carried out in accordance with 1.1.1-1(3). (4) Full Load Test

The engine is to be subjected to a full load test with the rpm for the maximum continuous output for 20 minutes. Basically, along with measuring performance of the engine in the range of the rpm at which the engine is being operated stably with the slottle fully open, observations of operating performances are to be carried out. The operating conditions are to be smooth without overheating or damage, and the performance is to be in compliance with the specifications.

(5) Minimum Speed Operating Test At the minimum rpm with the clutch engaged, operation is to be maintained for 10 minutes. Operation is to be smooth.

(6) Reverse Operation and Reverse Operating Test In case the engine is equipped for reverse operation, reverse operation and reverse operating test are to be carried out in conformity with 1.1.1-1(5).

(7) Governor Test (when governor is equipped) During the maximum continuous rpm, the load is to be abruptly changed from 100% to 0%, or from 0% to 100%, and the instantaneous speed variation, the time required for stabilization and the speed variation after stabilization are to be recorded. The instantaneous speed variation when the load is changed from 100% to 0% is to be 20% or less.

(8) Quick Speed Changing Test The revolution of the engine is to be changed 100 times, by opening/closing the throttle valve, between the minimum rpm under no load condition and 10% higher than the rpm corresponding to the maximum continuous output. The standard one cycle of the rpm changing is 15 seconds. Operation during the test is to be smooth.

(9) Engine-out-of-water Test An engine-out-of-water test is to be carried out in accordance with 1.1.1-3.

(10) Charging Test When the engine is equipped with a charger, charging capacity is to be ascertained.

(11) Insulation Resistance Test An insulation resistance test is to be carried out in accordance with 1.1.1-1(8).

(12) Endurance Test An endurance test is to be carried out in accordance with 1.1.1-1(9).

2 Tests of Motors for Rescue Boats (1) Test Rigs [7.3.2]

The motor, fitted with a suitable propeller, is to be placed in a test rig such that the propeller is completely submerged in a water tank, simulating service conditions.

(2) Running Test [7.3.3]


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The motor is to be run at the maximum continuous rpm using the maximum power obtainable for 20 min, and is not to be overheat or be damaged.

(3) Water Drench Test [7.3.4] The motor protective cover is to be removed and the motor thoroughly drenched with water, by hose, except for the intake to the carburettor. The motor is to be started and run at speed for at least 5 min while it is still being drenched. The motor is not to falter or be damaged by this test.

(4) Hot Start Test [7.3.5] While still in the test rig referred to in 1.1.2-2(1), the motor is to be run at idling speed in order to heat up the cylinder block. At the maximum temperature achievable, the motor is to be stopped and immediately restarted. This test is to be carried out at least twice. The motor is not to fail to restart.

(5) Manual start test [7.3.6, 7.3.7] (a) The motor is to be started at ambient temperature by manual means. The means are to be either a manual

automatic-rewind system or a pull cord round the top flywheel of the motor. The motor is to be started twice within 2 min of commencement of the start procedure.

(b) The motor is to be run until normal operating temperatures are reached, then it is to be stopped and started manually twice within 2 min, in accordance with (a).

(6) Cold start test [7.3.8, 7.3.9] (a) The motor, together with the fuel, fuel lines and battery, is to be placed in a chamber at a temperature of

-15 and allowed to remain until the temperature of all parts has reached the temperature of the chamber. The temperature of the fuel, battery and motor is to be measured for this test. The motor is to be started twice, within 2 min of commencement of the start procedure, and allowed to run long enough to demonstrate that it runs at operating speed. It is recommended that this period should not exceed 15 seconds.

(b) Where, in the opinion of the Society, having regard to the particular voyages in which the ship carrying the boat is constantly engaged, a lower temperature is appropriate, that lower temperature is to be substituted for -15 for the cold test.

3 Overhaul Inspection After the tests of 1.1.2-1 to 1.1.2-2, the motor is to be subjected to the overhaul examination. The motor is to show

no evidence of overheating or excessive wear.

Annex 5

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Chapter 2 PROCEDURES FOR PRODUCTION TESTS OF ENGINES FOR LIFEBOATS AND RESCUE BOATS

2.1 Performance Test

2.1.1 Items for Performance Tests The performance tests to be carried out are shown below. The procedures for these tests are to be in accordance with those specified in the procedures for Prototype Tests for Type Approval of Lifeboat Engines and Rescue Boat Engines unless otherwise specified. (1) Internal Combustion Engines for Lifeboats or Rescue Boats (including Reduction/Reverse Gears) (encluding

Outboard Motors) (a) Starting test (b) No load, low-speed operating test (c) No load, high-speed operating test (when no governor is equipped) (d) Load test

The load test is to be in accordance with Table 2. (e) Reversing operation and reversing test

The reversing test is to be performed with a load of 75% for 20 minutes. (f) Governor test (when equipped) (g) Charging test (h) Insulation resistance test (i) Overhaul inspection

(2) Outboard Motors for Rescue Boats (a) Starting test (b) No load, high-speed operating test (when no governor is equipped.) (c) Full load test (d) Minimum speed operating test (e) Reverse operation / reverse test (f) Governor test (when equipped) (g) Charging test (when a charger is equipped) (h) Insulation resistance test (i) Overhaul inspection

Table 2 Load Test

Load Operating time RPM Max. continuous output×0.25 20 minutes RPM is basically to be changed Max. continuous output×0.50 20 minutes in proportion to the cubic root Max. continuous output×0.75 20 minutes ratio of the load and the max. Max. continuous output×1.00 60 minutes continuous output. Max. continuous output×1.10 20 minutes

MAJOR CHANGES AND EFFECTIVE DATES

Amendments to the GUIDANCE FOR THE APPROVAL AND TYPE APPROVAL OF MATERIALS AND

EQUIPMENT FOR MARINE USE made between 1 January 2005 and 31 January 2006 and their effective dates

are as follows:

I-1 AMENDMENTS ON 1ST NOVEMBER 2005 (Notice No.32) AND ON 16TH DECEMBER 2005

(Notice No.34)

Part 6

Chapter 10 has been added.

EFFECTIVE DATE AND APPLICATION

1. The effective date of the amendments is 1 January 2007.

2. Notwithstanding the amendments to the Guidance, the current requirements may apply to

crankcase explosion relief valves of diesel engines installed on ships for which the date of

contract for construction* is before the effective date. *“contract for construction” is defined in IACS Procedural Requirement(PR) No.29 (Rev.1).

IACS PR No.29 (Rev.1)

Unless specified otherwise: 1. The date of “contract for construction” of a vessel is the date on which the contract to build the vessel is signed between the prospective

owner and the shipbuilder. This date is normally to be declared to the classification society by the party applying for the assignment of class to a newbuilding.

2. The date of “contract for construction” of a series of sister vessels, including specified optional vessels for which the option is ultimately exercised, is the date on which the contract to build the series is signed between the prospective owner and the shipbuilder.

For the purpose of this Procedural Requirement, sister vessels, are vessels built to the same approved plans for classification purposes. The optional vessels will be considered part of the same series of sister vessels if the option is exercised not later than 1 year after the contract to build the series was signed.

3. If a contract for construction is later amended to include additional vessels or additional options, the date of “contract for construction” for such vessels is the date on which the amendment to the contract, is signed between the prospective owner and the shipbuilder. The amendment to the contract is to be considered as a “new contract” to which 1. and 2. above apply.

Note:

1. This Procedural Requirement applies to all IACS Members and Associates. 2. This Procedural Requirement is effective for ships “contracted for construction” on or after 1 January 2005. 3. Sister vessels may have minor design alterations provided such alterations do not affect matters related to classification.

I-2 AMENDMENTS ON 1ST NOVEMBER 2005 (Notice No.32) AND ON 16TH DECEMBER 2005

(Notice No.34)

Part 7

Chapter 6 has been added.




crankcase oil mist detection arrangements of diesel engines installed on ships for which the

date of contract for construction* is before the effective date. *“contract for construction” is defined in IACS Procedural Requirement(PR) No.29 (Rev.1).







Note:


II AMENDMENTS ON 16th DECEMBER 2005 (Notice No.38)

In the “AMENDMENT TO THE GUIDANCE FOR THE APPROVAL AND TYPE APPROVAL OF MATERIALS AND EQUIPMENT FOR MARINE USE (Notice No. 60 dated 15th November 2004)”, the EFFECTIVE DATE AND APPLICATION for Amendment 2-1 has been amended as follows:




ships for which the date of contract for construction* is before the effective date. *“contract for construction” is defined in IACS Procedural Requirement(PR) No.29 (Rev.1).







Note:


III-1 AMENDMENTS ON 31ST JANUARY 2006 (Notice No.14)

Part 1

Chapter 1 Sub-paragraph 1.2.2-1(2)(i) has been amended.


1. The effective date of the amendments is 1 July 2006.


materials other than those for which the application for approval of manufacturing process is

submitted to the Society on and after the effective date.


Part 1

Chapter 1 Table 1.1-2 has been amended.




Part 1

Chapter 5 Table 1.5-1 has been amended.




materials other than those for which the application for survey is submitted to the Society on

and after the effective date.


Part 6

Chapter 2 Sub-paragraph 2.1.1(7) has been amended.

Sub-paragraph 2.4.2-9 has been amended.

Sub-paragraph 2.4.2-11 has been added.

Section 2.7 has been added.



2. Notwithstanding the amendments to the Guidance, the current requirements may apply to the

flexible hose assemblies approved by the Society before the effective date and installed on

ships for which the application for Classification Survey during Construction is submitted by

the valid date of their type approval.


Part 6

Chapter 6 Paragraph 6.2.3 has been amended.

Section 6.4 has been amended.

Sub-paragraph 6.9.1(4)(c) has been amended.

Table 6.6 has been amended.



2. Notwithstanding the amendments to the Guidance, the current requirements may apply to the

plastic pipes approved by the Society before the effective date and installed on ships for which

the application for Classification Survey during Construction is submitted by the valid date of

their type approval.

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